Reticulated material body support and method

ABSTRACT

A body support comprising a top layer of flexible visco-elastic material having an exposed convoluted top surface is disclosed. The flexible visco-elastic material can have a reticulated or non-reticulated cellular structure. In some embodiments, one or more other layers of the body support comprises reticulated visco-elastic foam, and can have at least one material property responsive to temperatures in the range of a user&#39;s body heat. In these and other embodiments, one or more of the other layers of flexible material comprises non-visco-elastic foam, and can be combined in a body support with one or more layers of visco-elastic foam. The body support can include one or more layers of other material types, including one or more layers of high-resilience polyurethane foam.

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority is hereby claimed to U.S. patent application Ser. No.11/166,594 filed on Jun. 24, 2005, the entire contents of which areincorporated herein by reference.

FIELD OF THE INVENTION

Conventional body supports can be found in a wide variety of shapes andsizes, and are often adapted for supporting one or more body parts of auser. As used herein, the term “body support” includes withoutlimitation any deformable element adapted to support one or more partsor all of a human or animal in any position. Examples of body supportsinclude mattresses, pillows, and cushions of any type, including thosefor use in beds, seats, and in other applications.

Many body supports are constructed entirely or partially out of foammaterial. For example, polyurethane foam is commonly used in manymattresses, pillows, and cushions, and can be used alone or incombination with other types of cushion materials. In many bodysupports, visco-elastic material is used, providing the body supportwith an increased ability to conform to a user and to thereby distributethe weight or other load of the user. Some visco-elastic body supportmaterials are also temperature sensitive, thereby also enabling the bodysupport to change shape based in part upon the temperature of thesupported body part.

Although the number and types of body supports constructed with one ormore visco-elastic materials continue to increase, the capabilities ofsuch materials are often underutilized. In many cases, thisunderutilization is due to poor body support design and/or the choice ofmaterial(s) used in the body support.

Based at least in part upon the limitations of existing body supportsand the high consumer demand for improved body supports in a widevariety of applications, new body supports are welcome additions to theart.

SUMMARY OF THE INVENTION

Some embodiments of the present invention provide a support cushion,comprising a first layer comprising visco-elastic foam having an exposedtop surface; and a bottom surface opposite the top surface and separatedfrom the top surface by a distance defining a thickness of the supportcushion; wherein at least a portion of the exposed top surface of thetop layer has a convoluted shape.

Further aspects of the present invention, together with the organizationand operation thereof, will become apparent from the following detaileddescription of the invention when taken in conjunction with theaccompanying drawings, wherein like elements have like numeralsthroughout the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectioned perspective view of a body support according to afirst embodiment of the present invention;

FIG. 1A is a detail view of the material in a layer of the body supportillustrated in FIG. 1;

FIG. 1B is a detail view of the material in another layer of the bodysupport illustrated in FIG. 1;

FIG. 2 is a sectioned perspective view of a body support according toanother embodiment of the present invention

FIG. 2A is a detail view of the material in a layer of the body supportillustrated in FIG. 2;

FIGS. 2B-6 are sectioned perspective views of body supports according toadditional embodiments of the present invention;

FIG. 7-9 are exploded perspective views of body supports according toadditional embodiments of the present invention;

FIGS. 10-12 are sectioned perspective views of body supports accordingto additional embodiments of the present invention;

FIG. 12A is a detail view of the material in a layer of the body supportillustrated in FIG. 12;

FIGS. 13-30 are sectioned perspective views of body supports accordingto additional embodiments of the present invention;

FIGS. 31-34 are exploded perspective views of body supports according toadditional embodiments of the present invention;

FIG. 35 is a sectioned perspective view of a pillow according to anembodiment of the present invention;

FIG. 36 is a sectioned perspective view of a pillow according to anotherembodiment of the present invention;

FIG. 37 is a perspective view of a pillow according to anotherembodiment of the present invention;

FIG. 38 is a cross-sectional view of the pillow illustrated in FIG. 37,taken along lines 38-38 of FIG. 37;

FIG. 39 is a perspective view of a pillow according to anotherembodiment of the present invention;

FIG. 40 is a cross-sectional view of the pillow illustrated in FIG. 39,taken along lines 40-40 of FIG. 39;

FIG. 41 is a perspective view of a pillow according to anotherembodiment of the present invention;

FIG. 42 is a cross-sectional view of the pillow illustrated in FIG. 41,taken along lines 42-42 of FIG. 41; and

FIG. 43 is an exploded perspective view of a body support and foundationassembly according to an embodiment of the present invention.

Before the various embodiments of the present invention are explained indetail, it is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangements ofcomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that phraseology and terminology used herein with referenceto device or element orientation (such as, for example, terms like“front”, “back”, “up”, “down”, “top”, “bottom”, and the like) are onlyused to simplify description of the present invention, and do not aloneindicate or imply that the device or element referred to must have aparticular orientation. In addition, terms such as “first”, “second”,and “third” are used herein and in the appended claims for purposes ofdescription and are not intended to indicate or imply relativeimportance or significance. The use of “including,” “comprising,” or“having” and variations thereof herein is meant to encompass the itemslisted thereafter and equivalents thereof as well as additional items.Unless limited otherwise, the terms “connected,” “coupled,” andvariations thereof herein are used broadly and encompass direct andindirect connections and couplings. In addition, the terms “connected”and “coupled” and variations thereof are not restricted to physical ormechanical connections or couplings.

DETAILED DESCRIPTION

A body support 102 according to an embodiment of the present inventionis illustrated in FIGS. 1, 1A, and 1B, and comprises two layers ofmaterial: a top layer 110 comprising open-celled non-reticulatedvisco-elastic foam (sometimes referred to as “memory foam” or “lowresilience foam”) and a bottom layer 112 comprising reticulatednon-visco-elastic foam. In some embodiments, the top layer 110 can restupon the bottom layer 112 without being secured thereto. However, inother embodiments, the top and bottom layers 110, 112 are secured to oneanother by adhesive or cohesive bonding material, by being bondedtogether during formation of the top and bottom layers 110, 112, bytape, hook and loop fastener material, conventional fasteners, stitchesextending at least partially through the top and bottom layers 110, 112,or in any other suitable manner.

Each of the top and bottom layers 110, 112 can be substantially flatbodies having substantially planar top and bottom surfaces 116, 118,120, 122 as shown in FIG. 1. However, in other embodiments, one or moreof the top and bottom surfaces 116, 118, 120, 122 of either or both topand bottom layers 110, 112 can be non-planar, including withoutlimitation surfaces having ribs, bumps, and other protrusions of anyshape and size, surfaces having grooves, dimples, and other aperturesthat extend partially or fully through the respective layer 110, 112,and the like. Such alternative surface shapes are described in greaterdetail below in connection with other embodiments of the presentinvention. Also, depending at least in part upon the application of thebody support 102 (i.e., the product defined by the body support 102 orin which the body support 102 is employed), either or both of the topand bottom layers 110, 112 can have shapes that are not flat. By way ofexample only, either or both layers 110, 112 can be generallywedge-shaped, can have a concave or convex cross-sectional shape, canhave a combination of convex and concave shapes, can have a stepped,faceted, or other shape, can have a complex or irregular shape, and/orcan have any other shape desired. Examples of such alternative shapesare presented in greater detail below in connection with otherembodiments of the present invention.

In some embodiments, the top layer 110 provides a relatively soft andcomfortable surface for a user's body or body portion (hereinafterreferred to as “body”). Coupled with the slow recovery characteristic ofthe visco-elastic foam, the top layer 110 can also conform to a user'sbody, thereby distributing the force applied by the user's body upon thetop layer 110. In some embodiments, the top layer 110 has a hardness ofat least about 30 N and no greater than about 175 N for desirablesoftness and body-conforming qualities. In other embodiments, a toplayer 110 having a hardness of at least about 40 N and no greater thanabout 110 N is utilized for this purpose. In still other embodiments, atop layer 110 having a hardness of at least about 40 N and no greaterthan about 75 N is utilized. Unless otherwise specified, the hardness ofa material referred to herein is measured by exerting pressure from aplate against a sample of the material having length and widthdimensions of 40 cm each (defining a surface area of the sample ofmaterial), and a thickness of 5 cm to a compression of 40% of anoriginal thickness of the material at approximately room temperature(e.g., 21-23 Degrees Celsius), wherein the 40% compression is held for aset period of time, following the International Organization ofStandardization (ISO) 2439 hardness measuring standard.

The top layer 110 can also have a density providing a relatively highdegree of material durability. The density of the foam in the top layer110 can also impact other characteristics of the foam, such as themanner in which the top layer 110 responds to pressure, and the feel ofthe foam. In some embodiments, the top layer 110 has a density of noless than about 30 kg/m³ and no greater than about 150 kg/m³. In otherembodiments, a top layer 110 having a density of at least about 40 kg/m³and no greater than about 125 kg/m³ is utilized. In still otherembodiments, a top layer 110 having a density of at least about 60 kg/m³and no greater than about 115 kg/m³ is utilized.

The visco-elastic foam of the top layer 110 can be selected forresponsiveness to any range of temperatures. However, in someembodiments, a temperature responsiveness in a range of a user's bodytemperatures (or in a range of temperatures to which the body support102 is exposed by contact or proximity to a user's body resting thereon)can provide significant advantages. For example, a visco-elastic foamselected for the top layer 110 can be responsive to temperature changesabove at least about 0° C. In some embodiments, the visco-elastic foamselected for the top layer 110 can be responsive to temperature changeswithin a range of at least about 10° C. In other embodiments, thevisco-elastic foam selected for the top layer 110 can be responsive totemperature changes within a range of at least about 15° C.

As used herein and in the appended claims, a material is considered“responsive” to temperature changes if the material exhibits a change inhardness of at least 10% measured by ISO Standard 3386 through the rangeof temperatures between 10 and 30 degrees Celsius.

With reference now to the illustrated embodiment of FIGS. 1, 1A, and 1B,the top layer 110 of the illustrated body support 102 comprises acellular structure of flexible visco-elastic polyurethane foam in whichthe walls of the individual cells are substantially intact. In someembodiments, the bottom layer 112 comprising reticulated foam can reduceheat in the top layer 110, due at least in part to the cellularstructure of the foam of the bottom layer 112. With reference to FIG.1B, for example, the cells of the foam of the bottom layer 112 areessentially skeletal structures in which many (if not substantially all)of the cell walls separating one cell from another do not exist. Inother words, the cells are defined by a plurality of supports or“windows” and by no cell walls, substantially no cell walls, or by asubstantially reduced number of cell walls. Such a cellular foamstructure is sometimes referred to as “reticulated” foam. In someembodiments, a foam is considered “reticulated” if at least 50% of thewalls defining the cells of the foam do not exist (i.e., have beenremoved or were never allowed to form during the manufacturing processof the foam).

Also, in some embodiments it is desirable that the bottom layer 112 ofreticulated non-visco-elastic foam be capable of providing some degreeof support that is substantially independent of temperatures experiencedby the top layer 110 when supporting a user's body (i.e., independent ofa user's body heat). Therefore, the bottom layer 112 can comprisereticulated non-visco-elastic foam that is substantially insensitive totemperature changes within a range of between about 10° C. and about 35°C. As used herein, a material is “substantially insensitive” totemperature changes if the material exhibits a change in hardness ofless than 10% measured by ISO Standard 3386 through the range oftemperatures between 10 and 30 degrees Celsius. In some embodiments, thebottom layer 112 can comprise reticulated non-visco-elastic foam that issubstantially insensitive to temperature changes within a range ofbetween about 15° C. and about 30° C. In still other embodiments, abottom layer 112 comprising reticulated non-visco-elastic foam that issubstantially insensitive to temperature changes within a range ofbetween about 15° C. and about 25° C. can be used.

By virtue of the skeletal cellular structure of the bottom layer 112illustrated in FIGS. 1 and 1B, heat in the top layer 110 can betransferred away from the top layer 110, thereby helping to keep arelatively low temperature in the top layer 110. Also, the reticulatednon-visco-elastic foam of the bottom layer 112 can enable significantlyhigher airflow into, out of, and through the bottom layer 112—acharacteristic of the bottom layer 112 that can also help to keep arelatively low temperature in the top layer 110.

Like the top layer 110, the bottom layer 112 can have a densityproviding a relatively high degree of material durability. Also, thedensity of the foam in the bottom layer 112 can also impact othercharacteristics of the foam, such as the manner in which the bottomlayer 112 responds to pressure, and the feel of the foam. In someembodiments, the bottom layer 112 has a density of no less than about 20kg/m³ and no greater than about 80 kg/M³. In other embodiments, a bottomlayer 112 having a density of at least about 25 kg/m³ and no greaterthan about 60 kg/m³ is utilized. In still other embodiments, a bottomlayer 112 having a density of at least about 30 kg/m³ and no greaterthan about 40 kg/m³ is utilized.

Also, in some embodiments, the bottom layer 112 has a hardness of atleast about 50 N and no greater than about 300 N. In other embodiments,a bottom layer 112 having a hardness of at least about 80 N and nogreater than about 250 N is utilized. In still other embodiments, abottom layer 112 having a hardness of at least about 90 N and no greaterthan about 180 N is utilized.

The body support 102 illustrated in FIGS. 1-1B can have a bottom layer112 that is at least as thick as the top layer 110, thereby providing asignificant ventilation and/or heat dissipation layer that, in someembodiments, is relatively temperature insensitive. In some embodiments,the bottom layer 112 is at least half the thickness as the top layer110. In other embodiments, the bottom layer 112 is at least about thesame thickness as the top layer 110. In still other embodiments, thebottom layer 112 is at least about 2 times as thick as the top layer110.

The body support 102 illustrated in FIGS. 1, 1A, and 1B is a mattress,mattress topper, overlay, or futon, and is illustrated in such form byway of example only. It will be appreciated that the features of thebody support 102 described above are applicable to any other type ofbody support having any size and shape. By way of example only, thesefeatures are equally applicable to head pillows, seat cushions, seatbacks, neck pillows, leg spacer pillows, eye masks, and any otherelement used to support or cushion any part or all of a human or animalbody. Accordingly, as used herein and in the appended claims, the term“body support” is intended to refer to any and all of such elements (inaddition to mattresses, mattress toppers, overlays, or futons). Itshould also be noted that each of the body supports described andillustrated herein is presented in a particular form, such as amattress, mattress topper, overlay, futon, or pillow. However, absentdescription herein to the contrary, any or all of the features of eachsuch body support can be applied to any other type of body supporthaving any other shape and size, including the various types of bodysupports mentioned above.

FIGS. 2 and 2A illustrate another embodiment of a body support accordingto the present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIGS. 1-1B. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIGS. 1-1B. Reference should be made to the descriptionabove in connection with FIGS. 1-1B for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIGS. 2 and 2A anddescribed below. Structure and features of the embodiment shown in FIGS.2 and 2A that correspond to structure and features of the embodiment ofFIGS. 1-1B are designated hereinafter in the 200 series of referencenumbers.

Like the embodiment illustrated in FIGS. 1-1B, the body support 202illustrated in FIGS. 2 and 2A has a top layer 210 comprising open-cellednon-reticulated visco-elastic foam and an underlying layer 212comprising reticulated non-visco-elastic foam. In some embodiments, thebody support 202 can therefore provide the desirable softness,body-conforming, ventilation, and heat transfer properties describedabove. The body support 202 illustrated in FIGS. 2 and 2A furthercomprises a bottom layer 214 beneath the layer of reticulatednon-visco-elastic foam 212. Therefore, the layer 212 of reticulatednon-visco-elastic foam is a middle layer 212 located between the top andbottom layers 210, 214 of the body support 202.

The bottom layer 214 of the body support 202 illustrated in FIGS. 2 and2A comprises a cellular structure of flexible polyurethane foam, as bestshown in FIG. 2A. In some embodiments, the middle layer 212 can restupon the bottom layer 214 without being secured thereto. However, inother embodiments, the middle and bottom layers 212, 214 are secured toone another in any of the manners described above with reference to thepossible types of connection between the top and bottom layers 110, 112in the illustrated embodiment of FIGS. 1-1B. In this regard, it shouldbe noted that absent description herein to the contrary, any adjacentlayers of material in any of the body support embodiments disclosedherein can be permanently or releasably secured to one another in any ofthe manners described above (with reference to the possible types ofconnection between the top and bottom layers 110, 112 in the illustratedembodiment of FIGS. 1-1B), or can be unconnected.

Each of the top, middle, and bottom layers 210, 212, 214 can besubstantially flat bodies having substantially planar top and bottomsurfaces 216, 218, 220, 222, 224, 226 as shown in FIG. 2. However, anyor all of the top and bottom surfaces can have any of the non-planarshapes described above in connection with the surfaces 116, 118, 120,122 in the illustrated embodiment of FIGS. 1-1B. Also, depending atleast in part upon the application of the body support 202 (i.e., theproduct defined by the body support 202 or in which the body support 202is employed), either or both of the top, middle, and bottom layers 210,212, 214 can have a shape that is not flat, including any of the shapesdescribed above in connection with the illustrated embodiment of FIGS.1-1B.

Absent description herein to the contrary, any or all of the layers ofmaterial in any of the body support embodiments disclosed herein can besubstantially flat, or can have any shape that is not flat, includingany of the shapes described above in connection with the illustratedembodiment of FIGS. 1-1B. Also absent description herein to thecontrary, the surfaces of either or both opposite faces of any or all ofthe layers of material in any of the body support embodiments disclosedherein can be substantially planar, or can instead have any of thenon-planar shapes described above in connection with the surfaces 116,118, 120, 122 in the illustrated embodiment of FIGS. 1-1B.

In some embodiments, the bottom layer 214 is a supportive layerproviding a relatively stiff substrate upon which the top and middlelayers 210, 212 lie, while still having a degree of deformability toprovide user comfort (to the extent that the user's weight affects theshape of the bottom layer 214). Therefore, the bottom layer 214 cancomprise a foam having a relatively high resilience capable of providingsignificant support to the top and middle layers 210, 212. The bottomlayer 214 can have a resilience greater than that of the other layers210, 212 in the body support 202. In some embodiments, the bottom layer214 has a hardness of at least about 50 N and no greater than about 300N for a desirable degree of support and comfort. In other embodiments, abottom layer 214 having a hardness of at least about 80 N and no greaterthan about 250 N is utilized for this purpose. In still otherembodiments, a bottom layer 214 having a hardness of at least about 90 Nand no greater than about 180 N is utilized.

Depending at least in part upon the thickness and material properties ofthe top and middle layers 210, 212, in some embodiments the bottom layer214 can be exposed to substantial body heat from a user resting upon thebody support 202. In such embodiments, the foam of the bottom layer 214can be selected to be substantially insensitive to temperature changes(as defined above) within a range of between about 10° C. and about 35°C., thereby retaining the supportive properties desired for the bottomlayer 214 throughout a range of body temperatures to which the bottomlayer 214 may be exposed. In some embodiments, the bottom layer 214 cancomprise foam that is substantially insensitive to temperature changeswithin a range of between about 15° C. and about 30° C. In still otherembodiments, a bottom layer 214 of foam that is substantiallyinsensitive to temperature changes within a range of between about 15°C. and about 25° C. can be used.

Like the top and middle layers 210, 212, the bottom layer 214 can have adensity providing a relatively high degree of material durability. Also,the density of the foam in the bottom layer 214 can also impact othercharacteristics of the foam, such as the manner in which the bottomlayer 214 responds to pressure, and the feel of the foam. In someembodiments, the bottom layer 214 has a density of no less than about 20kg/m³ and no greater than about 80 kg/m³. In other embodiments, a bottomlayer 214 having a density of at least about 25 kg/m³ and no greaterthan about 60 kg/m³ is utilized. In still other embodiments, a bottomlayer 214 having a density of at least about 30 kg/m³ and no greaterthan about 40 kg/m³ is utilized.

The body support 202 illustrated in FIG. 2 can have a bottom layer 214that is at least as thick as the combination of the top and middlelayers 210, 212, thereby providing substantial support for the top andmiddle layers 210, 212. In some embodiments, the bottom layer 214 is atleast about ⅔ of the combined thickness of the top and middle layers210, 212. Also, in some embodiments, the bottom layer 214 is at leastabout half the combined thickness of the top and middle layers 210, 212.

FIG. 2B illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIGS. 1-2A. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIGS. 1-2A. Reference should be made to the descriptionabove in connection with FIGS. 1-2A for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 2B and describedbelow. Structure and features of the embodiment shown in FIGS. 2B thatcorrespond to structure and features of the embodiment of FIGS. 1-2A aredesignated hereinafter with primed numbers in the 200 series ofreference numbers.

Like the embodiment illustrated in FIGS. 2 and 2A, the body support 202illustrated in FIG. 2B has a top layer 210′ comprising open-cellednon-reticulated visco-elastic foam, an underlying layer 212′ comprisingreticulated non-visco-elastic foam, and a bottom layer 214′ comprising acellular structure of flexible polyurethane foam (which, in someembodiments, comprises a foam having a relatively high resilience, atemperature insensitivity, a density, and/or a thickness as described ingreater detail above in connection with FIGS. 2 and 2A). Accordingly,the body support 202′ can provide the desirable softness,body-conforming, ventilation, and heat transfer properties describedabove, while also providing support for the top and middle layers 210′,212′.

As described above, some embodiments of the present invention employ oneor more layers of material having one or more surfaces that arenon-planar, such as surfaces that have ribs, bumps, and otherprotrusions of any shape and size, surfaces having grooves, dimples, andother apertures that extend partially or fully through the respectivelayer, and the like. The body support 202′ illustrated in FIG. 3 is anexample of such a body support. Also, the body support 202′ illustratedin FIG. 3 is an example of the manner in which a non-planar top surface216′ of the top layer 210′ can be employed to provide additionalfeatures for the body support 202′. In particular, the non-planar topsurface 216′ of the illustrated body support 202′ is convoluted. Thefeatures of the convoluted surface are described in greater detail belowin connection with the illustrated embodiment of FIG. 4. Alternatively,the non-planar top surface 216′ can take any of the other forms alsodescribed below in connection with the illustrated embodiment of FIG. 4and/or described above in connection with the illustrated embodiment ofFIGS. 1-1B.

In some embodiments, the non-planar top surface 216′ of the top layer210′ of visco-elastic foam can provide an enhanced degree of heatdissipation. Also or alternatively, the non-planar top surface 216′ canprovide desirable pressure distribution in a manner that is differentfrom that of a planar top surface 216′.

As described in greater detail below, any of the body supportembodiments disclosed herein can be provided with one or more coverscovering any part or all of such body supports. By way of example, thebody support 202′ illustrated in FIG. 2B has a cover 272′ enclosing allthree layers 210′, 212′, 214′ of the body support 202′. Further detailsregarding the features and construction of the cover 272′, as well asthe possible alternatives thereof, are discussed in greater detail belowin connection with the illustrated embodiment of FIG. 43.

Used in conjunction with a body support 202′ having a top layer 210′ ofvisco-elastic foam having a convoluted top surface 216′, the cover 272′can provide a desirable appearance for the body support 202′. The cover272′ can comprise a material that enables a user to see the shape ofsome or all of the non-planar top surface 216′ of the body support 202′.For example, although not illustrated in FIG. 2B, the top surface of thecover 272′ can show at least part of the convolutions of the underlyingtop layer 210′. The degree to which the shape of the non-planar topsurface 216′ is visible beneath the cover 272′ is dependent at least inpart upon the thickness of the cover 272′, the cover material, and thefit of the cover 272′ on the body support 202′ (e.g., taut or loosefit). It will be appreciated that the cover 272′ as described herein cancover any part or all of other non-planar top surfaces 216′ of the topvisco-elastic layer 210′, and can provide any degree of visibility ofthe underlying top layer shape.

Although the body support 202′ illustrated in FIG. 2B has a top layer210′ of visco-elastic foam (having a convoluted top surface 216′) atop alayer 212′ of reticulated non-visco-elastic foam and a layer 214′ ofrelatively high-resilience foam, it should be noted that any of the bodysupport embodiments disclosed herein having a top layer comprisingvisco-elastic foam (whether non-reticulated or reticulated as describedin greater detail below) can have a non-planar top surface as justdescribed.

FIG. 3 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIGS. 2 and 2A. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIGS. 2 and 2A. Reference should be made to thedescription above in connection with FIGS. 2 and 2A for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIG. 3 and described below. Structure and features of theembodiment shown in FIG. 3 that correspond to structure and features ofthe embodiment of FIGS. 2 and 2A are designated hereinafter in the 300series of reference numbers.

Like the body support 202 illustrated in FIGS. 2 and 2A, the bodysupport 302 illustrated in FIG. 3 comprises a top layer 310 ofopen-celled non-reticulated visco-elastic foam, beneath which lie middleand bottom layers 312, 314 of the body support 302. However, thematerials of the middle and bottom layers 312, 314 are switched comparedto the body support 202 illustrated in FIGS. 2 and 2A. Accordingly, themiddle layer 312 of the body support 302 illustrated in FIG. 3 comprisesa relatively resilient flexible polyurethane foam, and the bottom layer314 of the body support 302 comprises reticulated non-visco-elasticfoam. The relatively highly resilient foam of the middle layer 312 isdescribed in greater detail above in connection with the embodimentillustrated in FIGS. 2 and 2A, while the reticulated non-visco-elasticfoam of the bottom layer 314 is described in greater detail above inconnection with the embodiment illustrated in FIGS. 1-1B.

In the embodiment illustrated in FIG. 3, the non-reticulatedvisco-elastic foam can be provided with a desired degree of support bythe adjacent underlying layer of relatively highly resilient foam,rather than by a layer of such material underlying another intermediatelayer as shown in FIG. 2. In the structure illustrated in FIG. 3, themiddle layer 312 can provide enhanced user support, depending at leastin part upon the thicknesses of the top and middle layers 310, 312. Insome embodiments, the bottom layer 314 of reticulated non-visco-elasticfoam can reduce heat in the middle layer 312 (and in some embodiments,the top layer 310 as well), due at least in part to the reticulatedcellular structure of the foam of the bottom layer 314.

The body support 302 illustrated in FIG. 3 can have a middle layer 312that is at least about as thick as the top layer 310 to provide adesirable degree of support for the top layer 310. In some embodiments,the middle layer 312 can be at least about twice as thick as the toplayer 310 for this purpose. In other embodiments, a middle layer 312that is at least about three times as thick as the top layer 310 is usedfor this purpose.

With further reference to FIG. 3, the body support 302 can have a bottomlayer 314 that is at least about 0.07 times as thick as the combinedthickness of the top and middle layers 310, 312 to carry heat away fromthe middle layer 312 (and in some embodiments, the top layer 310 aswell). In some embodiments, the bottom layer 314 can be at least about0.15 times as thick as the combined thickness of the top and middlelayers 310, 312 for this purpose. In other embodiments, a bottom layer314 that is at least about 0.25 times as thick as the combined thicknessof the top and middle layers 310, 312 is used for this purpose.

FIG. 4 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIGS. 1-1B. Accordingly, thefollowing description focuses primarily upon the structure and featuresthat are different than the embodiments described above in connectionwith FIGS. 1-1B. Reference should be made to the description above inconnection with FIGS. 1-1B for additional information regarding thestructure and features, and possible alternatives to the structure andfeatures of the body support illustrated in FIG. 4 and described below.Structure and features of the embodiment shown in FIG. 4 that correspondto structure and features of the embodiment of FIGS. 1-1B are designatedhereinafter in the 400 series of reference numbers.

Like the body support 102 illustrated in FIGS. 1-1B, the body support402 illustrated in FIG. 4 comprises a top layer 410 comprisingopen-celled non-reticulated visco-elastic foam, beneath which lies abottom layer 412 comprising reticulated non-visco-elastic foam. However,the top surface 420 of the bottom layer 412 has a non-planar shapebeneath the substantially planar bottom surface 418 of the top layer410. In the embodiment of FIG. 4, the top surface 420 of the bottomlayer 412 has a plurality of protrusions 428 extending toward the toplayer 410. The protrusions 428 can be generally conical in shape, can befrusto-conical, or can have rounded tips as shown in FIG. 4.

The protrusions 428 of the bottom layer 412 and the bottom surface 418of the top layer 410 define a plurality of passages 430 between the topand bottom layers 410, 412. The passages 430 permit movement of airbetween the top and bottom layers 410, 412, thereby improving heattransfer within the body support 402. Also or alternatively, heat in oneor more locations of the body support 402 can be dissipated into andthrough the passages 430 between the top and bottom layers 410, 412. Theimproved heat transfer enabled by the passages 430 can be used to coolboth layers 410, 412, and can be particularly useful in reducing heat inthe top layer 410 closest to the user.

In some embodiments, the passages 430 between the top and bottom layers410, 412 have an average height of no less than about 0.5 cm and nogreater than about 10 cm. In other embodiments, the passages 430 have anaverage height of no less than about 1 cm and no greater than about 5cm. In still other embodiments, passages 430 having an average height ofno less than about 1 cm and no greater than about 3 cm are utilized. Itwill be appreciated that the average height of the passages 430 candepend at least in part upon the height of the protrusions 428 in theillustrated embodiment of FIG. 4. In other embodiments, the same averagepassage heights described above can still be employed using other typesof protrusions alone or in combination with apertures as described ingreater detail below.

As an alternative or in addition to the generally cone-shapedprotrusions 428 illustrated in FIG. 4, the top surface 420 of the bottomlayer 412 can have any other type of protrusion or combinations of typesof protrusions desired, including without limitation pads, bumps,pillars, and other localized protrusions, ribs, waves (e.g., having asmooth, sawtooth, or other profile), and other elongated protrusions,and the like. Also or alternatively, the top surface 420 of the bottomlayer 412 can have any number and type of apertures, including withoutlimitation recesses, dimples, blind holes, through holes, grooves, andthe like, any or all of which can be defined in whole or in part by anyof the types of protrusions just described.

The passages 430 between the top and bottom layers 410, 412 of the bodysupport 402 can be defined by protrusions 428, apertures, or anycombination of protrusions 428 and apertures. Although the protrusions428 and/or apertures need not necessarily be in any arrangement (e.g., arepeating or non-repeating pattern) on the bottom layer 412, in someembodiments the protrusions 428 are located on the bottom layer 412 insuch a manner. For example, the generally cone-shaped protrusions 428 ofthe bottom layer 412 in the embodiment illustrated in FIG. 4 areregularly spaced across the top surface 420 of the bottom layer 412. Insome embodiments, the areas of the top surface 420 located between thegenerally cone-shaped protrusions 428 can be recessed, and in someembodiments can cooperate with the protrusions 428 to resemble anegg-crate-shaped surface or any other surface shape desired.

Also, the protrusions 428 and/or apertures in the bottom layer 412 candefine passages 430 that have a constant or substantially constantheight. However, in other embodiments, the protrusions 428 and/orapertures in the bottom layer 412 can define passages 430 having aheight that varies at different locations between the top and bottomlayers 410, 412. Therefore, the passage height between the top andbottom layers 410, 412 can be expressed as an average height asdescribed above.

In the illustrated embodiment of FIG. 4, the protrusions 428 are locatedon substantially the entire top surface 420 of the bottom layer 412.However, in other embodiments, the protrusions 428 can be located onless than all of the entire top surface 420, such as in one or moreregions of the body support 402. Similarly, apertures at least partiallydefining the passages 430 can be defined in one or more regions or insubstantially the entire top surface 420 of the bottom layer 412.

As described above, passages 430 between the top and bottom layers 410,412 of the embodiment illustrated in FIG. 4 can be defined between asubstantially planar bottom surface 418 of the top layer 410 and aplurality of protrusions 428 and/or apertures on the top surface 420 ofthe bottom layer 412. In this regard, passages 430 capable of performingventilation and/or heat dissipating functions can be defined between thesubstantially planar bottom surface 418 of the top layer 410 and anynon-planar top surface 420 of the bottom layer 412. In otherembodiments, passages 430 can be defined between a non-planar bottomsurface 418 of the top layer 410 and a substantially planar top surface420 of the bottom layer 412. The non-planar bottom surface 418 of thetop layer 410 can have any of the protrusion and/or recess featuresdescribed above in connection with the top surface 420 of the bottomlayer 412 illustrated in FIG. 4. Therefore, the description aboveregarding the non-planar top surface 420 of the bottom layer 412 appliesequally to the bottom surface 418 of the top layer 410. In still otherembodiments, passages 430 can be defined between a non-planar bottomsurface 418 of the top layer 410 and a non-planar top surface 420 of thebottom layer 412. The non-planar surfaces 418, 420 can have any of theprotrusion and/or recess features described above in connection with thetop surface 420 of the bottom layer 412 illustrated in FIG. 4.

FIG. 5 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIGS. 2 and 2A. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIGS. 2 and 2A. Reference should be made to thedescription above in connection with FIGS. 2 and 2A for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIG. 5 and described below. Structure and features of theembodiment shown in FIG. 5 that correspond to structure and features ofthe embodiment of FIGS. 2 and 2A are designated hereinafter in the 500series of reference numbers.

As described in greater detail above with regard to the body support 202illustrated in FIGS. 2 and 2A, the body support 502 illustrated in FIG.5 comprises a top layer 510 comprising open-celled non-reticulatedvisco-elastic foam, a middle layer 512 comprising reticulatednon-visco-elastic foam, and a bottom layer 514 comprising flexiblecellular polyurethane foam having a relatively high resilience. However,the top surface 524 of the bottom layer 514 has a non-planar shapebeneath the substantially planar bottom surface 522 of the middle layer512. The non-planar shape of the top surface 524 can take any of theforms described above in connection with the non-planar top surface 420of the bottom layer 412 illustrated in FIG. 4, and can be defined by aplurality of protrusions 528 (as shown in FIG. 5) and/or a plurality ofapertures as also described above. Passages 530 can be defined betweenthe substantially planar bottom surface 522 of the middle layer 512 andthe non-planar top surface 524 of the bottom layer 514. In otherembodiments, such passages 530 can be defined between a non-planarbottom surface 522 of the middle layer 512 and a substantially planartop surface 524 of the bottom layer 514, or between a non-planar bottomsurface 522 of the middle layer 512 and a non-planar top surface 524 ofthe bottom layer 514, wherein the non-planar surface(s) can be definedin any of the manners described above in connection with the illustratedembodiment of FIG. 4.

Passages 530 running between the middle and bottom layers 512, 514illustrated in FIG. 5 can provide the body support 502 with a capacityfor ventilation and/or with an increased ability to dissipate heat fromthe middle layer 512 of reticulated non-visco-elastic foam, which canreceive a user's body heat from the top layer 510 of non-reticulatedvisco-elastic foam. The skeletal structure of the cells in the middlelayer 512 can enable heat to be transferred from the top layer 512 toand through the passages 530. Although heat transfer in lateraldirections (i.e., toward the edges of the body support 502) can stilloccur in the middle layer 512 of reticulated non-visco-elastic foambased at least in part upon the cell structure of such foam, thepassages 530 can enhance this heat transfer.

FIG. 6 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIG. 3. Accordingly, thefollowing description focuses primarily upon the structure and featuresthat are different than the embodiments described above in connectionwith FIG. 3. Reference should be made to the description above inconnection with FIG. 3 for additional information regarding thestructure and features, and possible alternatives to the structure andfeatures of the body support illustrated in FIG. 6 and described below.Structure and features of the embodiment shown in FIG. 6 that correspondto structure and features of the embodiment of FIG. 3 are designatedhereinafter in the 600 series of reference numbers.

As described in greater detail above with regard to the body support 302illustrated in FIG. 3, the body support 602 illustrated in FIG. 6comprises a top layer 610 comprising open-celled non-reticulatedvisco-elastic foam, a middle layer 612 comprising flexible cellularpolyurethane foam having a relatively high resilience, and a bottomlayer 614 comprising reticulated non-visco-elastic foam. However, thetop surface 620 of the middle layer 612 has a non-planar shape beneaththe substantially planar bottom surface 618 of the top layer 610. Thenon-planar shape of the top surface 620 can take any of the formsdescribed above in connection with the non-planar top surface 420 of thebottom layer 412 illustrated in FIG. 4, and can be defined by aplurality of protrusions 628 (as shown in FIG. 6) and/or a plurality ofapertures as also described above. Passages 630 can be defined betweenthe substantially planar bottom surface 618 of the top layer 610 and thenon-planar top surface 620 of the middle layer 612. In otherembodiments, the passages 630 can be defined between a non-planar bottomsurface 618 of the top layer 610 and a substantially planar top surface620 of the middle layer 612, or between a non-planar bottom surface 618of the top layer 610 and a non-planar top surface 620 of the middlelayer 612, wherein the non-planar surface(s) can be defined in any ofthe manners described above in connection with the illustratedembodiment of FIG. 4.

Passages 630 running between the top and middle layers 610, 612illustrated in FIG. 6 can provide the body support 602 with a capacityfor ventilation and/or with an increased ability to dissipate heat fromthe top layer 612 of non-reticulated visco-elastic foam (which can beimmediately adjacent a user's body upon the body support 602). Also, thepassages 630 can be particularly useful in providing ventilation and/orheat dissipation for the bottom layer 614 of the body support 602.

FIG. 7 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIGS. 1-1B. Accordingly, thefollowing description focuses primarily upon the structure and featuresthat are different than the embodiments described above in connectionwith FIGS. 1-1B. Reference should be made to the description above inconnection with FIGS. 1-1B for additional information regarding thestructure and features, and possible alternatives to the structure andfeatures of the body support illustrated in FIG. 7 and described below.Structure and features of the embodiment shown in FIG. 7 that correspondto structure and features of the embodiment of FIGS. 1-1B are designatedhereinafter in the 700 series of reference numbers.

Like the body support 102 illustrated in FIGS. 1-1B, the body support702 illustrated in FIG. 7 comprises a top layer 710 comprisingopen-celled non-reticulated visco-elastic foam, beneath which lies abottom layer 712 comprising reticulated non-visco-elastic foam. However,the bottom layer 712 further comprises portions of flexible cellularpolyurethane foam having a relatively high resilience. In particular,the bottom layer 712 has a first portion 732 comprising reticulatednon-visco-elastic foam having the same properties as described abovewith reference to the bottom layer 112 of the body support 102illustrated in FIG. 1, and second and third portions 734, 736 comprisingflexible cellular polyurethane foam having the same properties asdescribed above with reference to the bottom layer 214 of the bodysupport 202 illustrated in FIG. 2. Therefore, the second and thirdportions 734, 736 of the bottom layer 712 illustrated in FIG. 7 defineside borders of foam that is relatively stiff and supportive compared tothe conventional reticulated non-visco-elastic foam of the first portion732. Either or both of the second and third portions 734, 736 can have awidth W that is at least about 1 cm and is no greater than about 20 cm.In other embodiments, either or both of the second and third portions734, 736 can have a width W that is at least about 3 cm and is nogreater than about 15 cm. In still other embodiments, either or both ofthe second and third portions 734, 736 can have a width W that is atleast about 5 cm and is no greater than about 10 cm.

The second and third portions 734, 736 of the bottom layer 712 can haveany width desired, and therefore can be wider or narrower than thoseillustrated in FIG. 7. Also, the second and third portions 734, 736 canhave substantially constant widths as illustrated in FIG. 7, or can havewidths that vary along the sides 738, 740 of the bottom layer 712. Inaddition, the second and third portions 734, 736 need not necessarilyrun along the entire length of the sides 738, 740 of the bottom layer712 as shown in FIG. 7, and can instead run along any portion of thesides 738, 740 of the bottom layer 712 (e.g., only at the corners of thebottom layer 712, in two or more areas along either or both sides 738,740 of the bottom layer 712, and the like). In this regard, the secondand third portions 734, 736 need not necessarily be identical in width,length, or shape. Also, in other embodiments, the bottom layer 712 hasonly one of the second and third portions 734, 736.

As described above, the bottom layer 712 illustrated in FIG. 7 hassecond and third portions 734, 736 of flexible cellular foam having arelatively high resilience defining borders flanking a first portion 732of reticulated non-visco-elastic foam. In other embodiments, the secondand third portions 734, 736 of foam can instead be located at the ends742, 744 of the bottom layer 712 (e.g., at the head and foot of the bodysupport 702 at least partially defining a mattress, mattress topper,overlay, or futon), respectively, and in such locations can take any ofthe forms and shapes described above. In some embodiments, side and endborders of the relatively high resilience flexible cellular foam can beemployed, thereby surrounding or at least partially surrounding thefirst portion 732 of reticulated non-visco-elastic foam. Any combinationof borders and border locations of the relatively highly resilientflexible cellular foam can be utilized as desired.

By employing an underlying layer of reticulated non-visco-elastic foamhaving the properties described above, the first portion 732 of thebottom layer 712 can enhance ventilation of the body support 702 and/orheat dissipation from the top layer 710. In some embodiments, some typesof reticulated foam do not provide a relatively high degree of supportand resilience. Although such a foam can be acceptable in manyapplications, in some products, more supportive and resilient sides 738,740 and/or ends 742, 744 of the bottom layer 712 are desirable. Forexample, a mattress having such sides 738, 740 and/or ends 742, 744 canbetter support a user entering or exiting a resting location on themattress, and can better support a user sitting or leaning on an edge ofthe mattress.

Also, the location of a border of relatively highly resilient flexiblecellular foam as described above can be selected based upon the desiredheat dissipating qualities of the body support 702. For example, theborderless ends 742, 744 of the body support 702 illustrated in FIG. 7can enable increased ventilation and/or heat dissipation from the firstportion 732 of reticulated non-visco-elastic foam in the bottom layer712. Similarly, body supports 702 having bordered ends 742, 744 of therelatively highly resilient flexible cellular foam and borderless sides738, 740 can provide similar results. In those embodiments in whichventilation and heat dissipation through the ends and/or sides of thefirst portion 732 of reticulated non-visco-elastic foam is lessimportant than additional resilience and support in such locations, aborder of the relatively highly resilient flexible cellular foam can beprovided in such locations.

In still other embodiments of the present invention, the bottom layer712 of the body support 702 comprises two or more regions of reticulatednon-visco-elastic foam, each at least partially surrounded by one ormore borders of relatively highly resilient and flexible cellularpolyurethane foam. The reticulated non-visco-elastic foam can have theproperties described above with reference to the bottom layer 112 of thebody support 102 illustrated in FIG. 1, while the relatively highlyresilient flexible cellular foam of the border(s) can have the sameproperties as described above with reference to the bottom layer 214 ofthe body support 202 illustrated in FIG. 2. In some embodiments, thebottom layer 712 can have two or more regions defining “islands” ofreticulated non-visco-elastic foam surrounded by one or more borders ofrelatively highly resilient flexible cellular foam. In these and otherembodiments, one or more of the regions of reticulated non-visco-elasticfoam can be open to one or more sides or ends 738, 740, 742, 744 of thebottom layer 712 and/or can be connected to another of the regions ofreticulated non-visco-elastic foam.

In those embodiments in which the body support 702 has a bottom layer712 comprising one or more regions of reticulated non-visco-elasticfoam, the regions can be in any location or locations across the bottomlayer 712. For example, the regions of reticulated non-visco-elasticfoam can be located in areas of greatest contact and/or pressure from auser lying upon the body support 702, such as near the shoulders, back,and buttocks of a user. Also, such regions of reticulatednon-visco-elastic foam can have any shape (such as rectangular,trapezoidal, triangular, or other polygonal shapes, round, oval, orother rotund shapes, irregular shapes, and the like), and can have anysize desired.

FIG. 8 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIG. 7. Accordingly, thefollowing description focuses primarily upon the structure and featuresthat are different than the embodiments described above in connectionwith FIG. 7. Reference should be made to the description above inconnection with FIG. 7 for additional information regarding thestructure and features, and possible alternatives to the structure andfeatures of the body support illustrated in FIG. 8 and described below.Structure and features of the embodiment shown in FIG. 8 that correspondto structure and features of the embodiment of FIG. 7 are designatedhereinafter in the 800 series of reference numbers.

Like the embodiment of the present invention illustrated in FIG. 7, thebody support 802 illustrated in FIG. 8 comprises a top layer 810comprising open-celled non-reticulated visco-elastic foam, beneath whichlies a bottom layer 812 comprising reticulated non-visco-elastic foamand relatively highly resilient and flexible cellular polyurethane foam.However, the first portion 832 of the bottom layer 812 comprisesflexible cellular polyurethane foam having the same properties describedabove with reference to the bottom layer 214 of the body support 202illustrated in FIG. 2, and the border 846 of the bottom layer 812comprises reticulated non-visco-elastic foam having the same propertiesdescribed above with reference to the bottom layer 112 of the bodysupport 102 illustrated in FIG. 1. The border 846 can extend fullyaround the first portion 832 of relatively highly resilient flexiblecellular foam as shown in FIG. 8, or can extend partially around thefirst portion 832 of relatively highly resilient flexible cellular foam(e.g., having portions flanking the first portion 832 as described abovewith reference to the embodiment of FIG. 7, or having one or moreportions shaped and located in any of the manners described above inconnection with the illustrated embodiment of FIG. 7).

In short, the first portion 832 and border 846 illustrated in FIG. 8 canhave any of the shapes, positions, and arrangements described above inconnection with the embodiment of FIG. 7. Also, the materials of thebottom layer region(s) and border(s) described above in connection withFIG. 7 (i.e., two or more regions or islands of material at leastpartially surrounded by one or more borders) can be reversed, in whichcase the two or more regions or islands of the relativelyhighly-resilient flexible cellular foam can be at least partiallysurrounded by one or more borders of reticulated non-visco-elastic foam.

By utilizing a border 846 of reticulated non-visco-elastic foampartially or fully surrounding the first portion 832 comprisingrelatively highly-resilient flexible cellular foam in the bottom layer812, the body support 802 can have an enhanced ability to provideventilation of the body support 802 and/or to dissipate heat from thefirst portion 832 and/or from the top layer 810. The peripheral locationof the border 846 illustrated in FIG. 8 is desirable for performing thisfunction, enabling heat to be drawn from a central area of the top andbottom layers 810, 812 toward the edges of the body support 802, whereheat can be more readily dissipated from the body support 802.

FIG. 9 illustrates another embodiment of a body support according to thepresent invention. This embodiment employs much of the same structureand has many of the same properties as the embodiments of the bodysupport described above in connection with FIG. 7. Accordingly, thefollowing description focuses primarily upon the structure and featuresthat are different than the embodiments described above in connectionwith FIG. 7. Reference should be made to the description above inconnection with FIG. 7 for additional information regarding thestructure and features, and possible alternatives to the structure andfeatures of the body support illustrated in FIG. 9 and described below.Structure and features of the embodiment shown in FIG. 9 that correspondto structure and features of the embodiment of FIG. 7 are designatedhereinafter in the 900 series of reference numbers.

Like the body support 702 illustrated in FIG. 7, the body support 902illustrated in FIG. 9 comprises a top layer 910 comprising open-cellednon-reticulated visco-elastic foam, beneath which lies a bottom layer912 comprising a first portion 932 comprising reticulatednon-visco-elastic foam flanked by second and third portions 934, 936comprising relatively highly resilient flexible cellular foam. The firstportion 932 can comprise reticulated non-visco-elastic foam having thesame properties described above with reference to the bottom layer 112of the body support 102 illustrated in FIG. 1. The second and thirdportions 934, 936 can comprise relatively highly resilient flexiblecellular foam having the same properties described above with referenceto the bottom layer 214 of the body support 202 illustrated in FIG. 2.Also, the portions 932, 934, 936 can have any of the shapes andarrangements described above with reference to FIG. 7, such as a border946 of the relatively highly resilient flexible cellular foam partiallyor entirely surrounding the reticulated non-visco-elastic foam portion932, borders of the relatively highly resilient flexible cellular foamon any of the sides and ends of the bottom layer 912, islands or otherregions of the reticulated non-visco-elastic foam at least partiallysurrounded by the relatively highly resilient flexible cellular foam,and the like.

If desired, the bottom surface 918 of the top layer 910 and/or the topsurface 920 of the bottom layer 912 can have a non-planar shape defininga plurality of passages 930 between the top and bottom layers 910, 912.In the illustrated embodiment of FIG. 9, for example, passages 930 aredefined between a substantially planar bottom surface 918 of the toplayer 910 and a non-planar top surface 920 of the bottom layer 912. Thenon-planar shape of the top surface 920 of the bottom layer 912 can takeany of the forms described above in connection with the non-planar topsurface 420 of the bottom layer 412 illustrated in FIG. 4, and can bedefined by a plurality of protrusions 928 and/or a plurality ofapertures as also described above.

The passages 930 between the bottom surface 918 of the top layer 910 andthe top surface 920 of the bottom layer 912 can provide enhancedventilation and/or heat dissipation of the body support 902. Thepassages 930 can be particularly useful in reducing heat in regions ofthe body support 902. The passages 930 can supplement the ability of thereticulated non-visco-elastic foam of the first portion 932 to dissipateheat between the second and third portions 934, 936 of relatively highlyresilient flexible cellular foam and the top layer 910 ofnon-reticulated visco-elastic foam.

Although the first portion 932 of the bottom layer 912 illustrated inFIG. 9 comprises reticulated non-visco-elastic foam, and the second andthird portions 934, 936 of the bottom layer 912 comprise a relativelyhighly resilient flexible cellular foam, the material of the firstportion 932 and the material of the second and third portions 934, 936can be reversed in other embodiments, thereby providing a structuresimilar to those described above in connection with the embodimentillustrated in FIG. 8. Accordingly, the description above regarding thebody support 802 illustrated in FIG. 8 applies equally to suchalternative embodiments of FIG. 9.

With continued reference to the illustrated embodiment of FIG. 9, thefirst and second layers 910, 912 of the body support 902 can have acover 948 comprising reticulated non-visco-elastic foam. The reticulatednon-visco-elastic foam of the cover 948 can have the same properties asdescribed above with reference to the bottom layer 112 of the bodysupport 102 illustrated in FIG. 1. Also, the reticulatednon-visco-elastic foam of the cover 948 can cover any portion of thefirst and second layers 910, 912. For example, the cover 948 illustratedin FIG. 9 covers substantially the entire top surface 916 of the toplayer 910. In other embodiments, the cover 948 can also or instead coverany portion or all of the sides and ends of the first and second layers910, 912, and/or can underlie any portion or all of the bottom surface924 of the bottom layer 912. In some embodiments, the cover 948substantially entirely surrounds the first and second layers 910, 912.

The reticulated non-visco-elastic foam cover 948 can be selected toprovide a heightened degree of fire resistance to the body support 902,and in some countries and/or localities can be utilized to meet firecodes calling for such fire resistance. Although other materials capableof meeting such fire code requirements can be employed, the use ofreticulated non-visco-elastic foam can provide improved ventilation forthe surface(s) of the first and/or second layers 910, 912 covered by thereticulated non-visco-elastic foam cover 948. As described above,reticulated non-visco-elastic foam can reduce the amount of heat inadjacent areas of a body support, based at least in part upon theskeletal cellular structure of the reticulated foam. Therefore, in someembodiments, the reticulated non-visco-elastic foam cover 948 canprovide a degree of fire resistance while also dissipating heat from theadjacent first and/or second layers 910, 912 covered by the reticulatedfoam cover 948 in use of the body support 902.

With continued reference to the embodiment of FIG. 9, the visco-elasticnature of t h e top layer 910 can provide a relatively comfortablesubstrate for a user's body, can at least partially conform to theuser's body to distribute force applied thereby, and can be selected forresponsiveness to a range of temperatures generated by the body heat ofa user. In some embodiments, the reticulated foam cover 948 (ifemployed) has a maximum thickness through which these properties canstill be exhibited. Although the desirable tactile feel of thevisco-elastic first layer 910 can be blocked in some embodiments by thereticulated non-visco-elastic foam cover 948, the other desirableproperties of the visco-elastic material of the first layer 910 arestill experienced through a sufficiently thin reticulatednon-visco-elastic foam cover 948. In some embodiments, the reticulatednon-visco-elastic foam cover 948 has a maximum thickness of about 1 cm.In other embodiments, the reticulated non-visco-elastic foam cover 948has a maximum thickness of about 2 cm. In still other embodiments, thereticulated non-visco-elastic foam cover 948 has a maximum thickness ofabout 5 cm.

As also shown in FIG. 9, the top surface 916 of the top layer 910 canhave a non-planar shape defining a plurality of passages 930 between thereticulated non-visco-elastic foam cover 948 and the top layer 910. Inother embodiments, the passages 930 can be defined between a non-planarbottom surface 952 of the reticulated non-visco-elastic foam cover 948and a substantially planar top surface 916 of the top layer 910 and/orbetween a non-planar bottom surface 952 of the reticulatednon-visco-elastic foam cover 948 and a non-planar top surface 916 of thetop layer 910. Enhanced user comfort, ventilation, and/or heatdissipation can be achieved in some embodiments by such passages 930.

The non-planar shape of the top surface 916 illustrated in FIG. 9(and/or of the bottom surface 952 of the reticulated non-visco-elasticfoam cover 948) can take any of the forms described above in connectionwith the non-planar top surface 420 of the bottom layer 412 illustratedin FIG. 4, and can be defined by a plurality of protrusions 928 and/or aplurality of apertures as also described above.

The passages 930 between the bottom surface 952 of the reticulatednon-visco-elastic foam cover 948 and the top surface 916 of the toplayer 910 can provide a degree of ventilation and/or enhanced heatdissipation for the body support 902. These passages 930 can beparticularly useful in reducing heat in regions of the body support 902.These passages 930 can also supplement the ability of the reticulatednon-visco-elastic foam of the cover 948 to dissipate heat between thecover 948 and the top layer 910.

The reticulated non-visco-elastic foam cover 948 illustrated in FIG. 9is utilized in conjunction with a top layer 910 comprisingnon-reticulated visco-elastic foam, and a bottom layer 912 comprising afirst portion 932 of reticulated non-visco-elastic foam flanked bysecond and third portions 934, 936 of relatively highly resilientflexible cellular foam as described above. However, it should be notedthat the reticulated non-visco-elastic foam cover 948 (and thealternative embodiments of the reticulated non-visco-elastic foam cover948 described above) can be utilized to cover any or all surfaces of anyof the body supports described and/or illustrated herein.

FIG. 10 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 3. Accordingly, thefollowing description focuses primarily upon the structure and featuresthat are different than the embodiments described above in connectionwith FIG. 3. Reference should be made to the description above inconnection with FIG. 3 for additional information regarding thestructure and features, and possible alternatives to the structure andfeatures of the body support illustrated in FIG. 10 and described below.Structure and features of the embodiment shown in FIG. 10 thatcorrespond to structure and features of the embodiment of FIG. 3 aredesignated hereinafter in the 1000 series of reference numbers.

Like the body support 302 illustrated in FIG. 3, the body support 1002illustrated in FIG. 10 comprises a first layer 1010 comprisingopen-celled non-reticulated visco-elastic foam, a second layer 1012comprising a relatively highly resilient flexible cellular foam beneaththe first layer 1010, and a third layer 1014 comprising reticulatednon-visco-elastic foam beneath the second layer 1012 of relativelyhighly resilient flexible cellular foam. The properties of thenon-reticulated visco-elastic foam in the first layer 1010 and thereticulated non-visco-elastic foam in the third layer 1014 are describedabove in connection with the top and bottom layers 110, 112,respectively, in the illustrated embodiment of FIGS. 1-1B. Theproperties of the relatively highly resilient flexible cellular foam inthe second layer 1012 are described above in connection with the bottomlayer 214 in the illustrated embodiment of FIGS. 2 and 2A.

In the embodiment illustrated in FIG. 10, the non-reticulatedvisco-elastic foam of the first layer 1010 can be provided with adesired degree of support by the adjacent underlying layer 1012 ofrelatively highly resilient flexible cellular foam. As described above,the skeletal cellular structure of the reticulated non-visco-elasticfoam of the third layer 1014 can function to reduce heat in the secondlayer 1012 (and in some embodiments, the first layer 1010 as well).

In some embodiments, the reticulated non-visco-elastic foam of the thirdlayer 1014 is less resilient and/or less supportive than the foams thatcan be employed for the second layer 1012 (e.g., the relatively highlyresilient flexible cellular foam described above in connection with theillustrated embodiment of FIGS. 2 and 2A). Although the second layer1012 can be increased in thickness to accommodate for the less resilientand/or less supportive reticulated non-visco-elastic foam layer 1014,the ability to dissipate heat (via the resulting relatively thinnerreticulated foam material) can be reduced. In some embodiments, a fourthlayer 1054 of relatively highly resilient flexible cellular foam islocated beneath the third layer 1014 of reticulated non-visco-elasticfoam, thereby providing additional support to the first, second, andthird layers 1010, 1012, 1014, and supplementing the resilience andsupport provided by the second layer 1012. In the illustrated embodimentof FIG. 10, the fourth layer 1054 comprises substantially the samerelatively highly resilient flexible cellular foam as the second layer1012. However, in other embodiments, the relatively highly resilientflexible cellular foam of the fourth layer 1054 is different than thatof the second layer 1012.

If desired, a fifth layer 1056 of reticulated non-visco-elastic foam canlie beneath the fourth layer 1054, thereby providing an increasedcapability to dissipate heat from the body support 1002. In theillustrated embodiment of FIG. 10, the fifth layer 1056 comprisessubstantially the same reticulated non-visco-elastic foam as the thirdlayer 1014. However, in other embodiments, the reticulatednon-visco-elastic foam of the fifth layer 1056 is different than that ofthe third layer 1014. In this regard, any number of alternating layersof relatively highly resilient flexible cellular foam and reticulatednon-visco-elastic foam can lie beneath the first layer 1010 ofnon-reticulated visco-elastic foam. Such body supports 1002 cantherefore have a desirable degree of resilience and support (from two ormore layers of relatively highly resilient flexible cellular foam) whilestill retaining the desirable heat dissipative capabilities describedabove (from two or more layers of reticulated non-visco-elastic foam).In some embodiments, heat in one or more areas of the body support 1002can be transmitted through one or more layers of the relatively highlyresilient flexible cellular foam for dissipation through the alternatinglayers of reticulated non-visco-elastic foam.

FIG. 11 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIGS. 2 and 2A.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIGS. 2 and 2A. Reference should be made to thedescription above in connection with FIGS. 2 and 2A for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIG. 11 and described below. Structure and features ofthe embodiment shown in FIG. 11 that correspond to structure andfeatures of the embodiment of FIGS. 2 and 2A are designated hereinafterin the 1100 series of reference numbers.

Like the body support 202 illustrated in FIGS. 2 and 2A, the bodysupport 1102 illustrated in FIG. 11 comprises a first layer 1110comprising open-celled non-reticulated visco-elastic foam, a secondlayer 1112 comprising reticulated non-visco-elastic foam beneath thefirst layer 1110, and a third layer 1114 comprising relatively highlyresilient flexible cellular foam beneath the second layer 1112. Theproperties of the non-reticulated visco-elastic foam in the first layer1010 and the reticulated non-visco-elastic foam in the second layer 1012are described above in connection with the top and bottom layers 110,112, respectively, in the illustrated embodiment of FIGS. 1-1B. Theproperties of the relatively highly resilient flexible cellular foam inthe third layer 1014 are described above in connection with the bottomlayer 214 in the illustrated embodiment of FIGS. 2 and 2A.

In the embodiment illustrated in FIG. 11, the skeletal cellularstructure of the reticulated foam of the second layer 1112 can functionto dissipate heat in the first layer 1110 of non-reticulatedvisco-elastic foam, while the first and second layers 1110, 1112 can beprovided with a desirable degree of support by the underlying layer 1114of relatively highly resilient flexible cellular foam. Compared to thesecond layer 1012 of body support 1002 illustrated in FIG. 10, thesecond layer 1112 of reticulated foam in the body support 1102 of FIG.11 can provide an increased amount of heat dissipation and/orventilation, but with a less resilient upper portion of the body support1102 (in some embodiments, and depending at least in part upon thethickness of the first and second layers 1110, 1112). Therefore, thefirst three layers 1010, 1012, 1014, 1110, 1112, 1114 of the bodysupports 1002, 1102 illustrated in FIGS. 10 and 11 can have differentqualities adapted for the comfort and taste of different users.

With continued reference to the illustrated embodiment of FIG. 11, insome embodiments, the reticulated non-visco-elastic foam of the secondlayer 1112 is less resilient and/or less supportive than the foams thatcan be employed for the third layer 1114 (e.g., the relatively highlyresilient flexible cellular foam described above in connection with theillustrated embodiment of FIGS. 2 and 2A). Although the third layer 1114can be increased in thickness to accommodate for the less resilientand/or less supportive reticulated non-visco-elastic foam layer 1112,the advantages relating to heat dissipation from the relatively thinnerreticulated foam material can be reduced. In some embodiments, a fourthlayer 1154 of reticulated non-visco-elastic foam is located beneath thethird layer 1114 of relatively highly resilient flexible cellular foam,thereby providing an increased capability to dissipate heat from thebody support 1102. In the illustrated embodiment of FIG. 11, the fourthlayer 1154 comprises substantially the same reticulatednon-visco-elastic foam as the second layer 1112. However, in otherembodiments, the reticulated non-visco-elastic foam of the fourth layer1154 is different than that of the second layer 1112.

In some embodiments, a fifth layer 1156 of relatively highly resilientflexible cellular foam is located beneath the fourth layer 1154 ofreticulated non-visco-elastic foam, thereby providing additional supportto the first, second, third, and fourth layers 1110, 1112, 1114, and1154, and supplementing the resilience and support provided by the thirdlayer 1014. In the illustrated embodiment of FIG. 11, the fifth layer1154 comprises substantially the same relatively highly resilientflexible cellular foam as the third layer 1114. However, in otherembodiments, the relatively highly resilient flexible cellular foam ofthe fifth layer 1154 is different than that of the third layer 1112. Asdescribed above, any number of alternating layers of relatively highlyresilient flexible cellular foam and reticulated non-visco-elastic foamcan lie beneath the first layer 1010 of non-reticulated visco-elasticfoam to provide a desired degree of resilience and support while stillretaining the ventilation and/or heat dissipative capabilities alsodescribed above. In some embodiments, heat in one or more areas of thebody support 1102 can be transmitted through one or more layers of therelatively highly resilient flexible cellular foam for dissipationthrough the alternating layers of reticulated non-visco-elastic foam.

FIGS. 12 and 12A illustrate another embodiment of a body supportaccording to the present invention. The body support 1202 illustrated inFIGS. 12 and 12A comprises two layers of material: a top layer 1210comprising reticulated visco-elastic foam and a bottom layer 1212comprising a cellular structure of polyurethane foam.

Like the foam of the top layer 10 described above with reference to theembodiment of the body support 102 illustrated in FIGS. 1, 1A, and 1B(and utilized in the other embodiments illustrated and/or describedabove in connection with FIGS. 1-11), the reticulated foam of the toplayer 1210 is a visco-elastic foam, and therefore falls generally withinthe category of foams otherwise known as “memory foams” or “lowresilience foams”. However, the reticulated visco-elastic foam of thetop layer 1210 has a structure that is significantly different than thatof non-reticulated visco-elastic foams (such as those described above inconnection with the embodiments of FIGS. 1-11), and can thereforeprovide body supports with significantly different properties as willnow be described.

As shown in FIG. 12A, the reticulated visco-elastic foam of the toplayer 1210 is a cellular foam structure in which the cells of thevisco-elastic foam are essentially skeletal. Many (if not substantiallyall) of the cell walls separating one cell from another do not exist. Inother words, the cells of the reticulated visco-elastic foam are definedonly by a plurality of supports or “windows” and by no cell walls,substantially no cell walls, or by a substantially reduced number ofcell walls. In some embodiments, the visco-elastic foam is considered“reticulated” if at least 50% of the walls defining the cells of thevisco-elastic foam do not exist (i.e., have been removed or were neverallowed to form during the manufacturing process of the visco-elasticfoam).

By virtue of the skeletal cellular structure of the reticulatedvisco-elastic foam of the top layer 1210 illustrated in FIGS. 12 and12A, heat in the top layer 1210 can be transferred away from the sourceof heat (e.g., a user's body), thereby helping to prevent one or moreareas of the top layer 1210 from reaching an undesirably hightemperature. Also, the reticulated structure of the foam in the toplayer 1210 enables significantly higher airflow into, out of, andthrough the top layer 1210—a characteristic of the top layer 1210 thatcan reduce heat in the top layer 1210. At the same time, thevisco-elastic nature of the foam in the top layer 1210 providesdesirable tactile contact and pressure responsiveness for user comfort.In this regard, the reticulated visco-elastic foam of some embodimentshas a reduced hardness level, thereby providing a relatively soft andcomfortable surface for a user's body. In conjunction with the slowrecovery characteristic of the reticulated visco-elastic material, thetop layer 1210 can also at least partially conform to the user's body,thereby distributing the force applied by the user's body upon the toplayer 1210.

In some embodiments, the top layer 1210 of reticulated visco-elasticfoam has a hardness of at least about 20 N and no greater than about 150N for desirable softness and pressure-responsive qualities. In otherembodiments, a top layer 1210 having a hardness of at least about 30 Nand no greater than about 100 N is utilized for this purpose. In stillother embodiments, a top layer 1210 having a hardness of at least about40 N and no greater than about 85 N is utilized.

The top layer 1210 can also have a density providing a relatively highdegree of material durability. The density of the foam in the top layer1210 can also impact other characteristics of the foam, such as themanner in which the top layer 1210 responds to pressure, and the feel ofthe foam. In some embodiments, the top layer 1210 has a density of noless than about 30 kg/m³ and no greater than about 175 kg/m³. In otherembodiments, a top layer 1210 having a density of at least about 50kg/m³ and no greater than about 130 kg/m³ is utilized. In still otherembodiments, a top layer 1210 having a density of at least about 60kg/m³ and no greater than about 110 kg/m³ is utilized.

The reticulated visco-elastic foam of the top layer 1210 can be selectedfor responsiveness to any range of temperatures. However, in someembodiments, a temperature responsiveness in a range of a user's bodytemperatures (or in a range of temperatures to which the body support1202 is exposed by contact or proximity to a user's body restingthereon) can provide significant advantages. For example, a reticulatedvisco-elastic foam selected for the top layer 1210 can be responsive totemperatures changes (as defined above) above at least 0° C. In someembodiments, the reticulated visco-elastic foam selected for the toplayer 1210 can be responsive to temperature changes within a range of atleast about 10° C. In other embodiments, the reticulated visco-elasticfoam selected for the top layer 1210 can be responsive to temperaturechanges within a range of at least about 15° C.

As described above, the bottom layer 1212 of the body support 1202illustrated in FIGS. 12 and 12A comprises a cellular structure ofpolyurethane foam. This layer of foam is a supportive layer providing arelatively stiff but flexible and resilient substrate upon which the toplayer 1210 lies. The resiliently deformable nature of the bottom layer1212 can therefore provide a degree of user comfort to the extent thatthe user's weight affects the shape of the bottom layer 1212. The foamof the bottom layer 1212 can be relatively highly resilient, and in someembodiments has a hardness of at least about 50 N and no greater thanabout 300 N for a desirable degree of support and comfort. In otherembodiments, a bottom layer 1212 having a hardness of at least about 80N and no greater than about 250 N is utilized for this purpose. In stillother embodiments, a bottom layer 1212 having a hardness of at leastabout 90 N and no greater than about 180 N is utilized.

Depending at least in part upon the thickness and material properties ofthe top layer 1210, in some embodiments the bottom layer 1212 can beexposed to substantial body heat from a user resting upon the bodysupport 1202. In such embodiments, the foam of the bottom layer 1212 canbe selected to be substantially insensitive to temperature changes (asdefined above) within a range of between about 10° C. to about 35° C.,thereby retaining the supportive properties desired for the bottom layer1212 throughout a range of body temperatures to which the bottom layer1212 may be exposed. In some embodiments, the bottom layer 1212 cancomprise foam that is substantially insensitive to temperature changeswithin a range of between about 15° C. to about 30° C. In still otherembodiments, a bottom layer 1212 of foam that is substantiallyinsensitive to temperature changes within a range of between about 15°C. to about 25° C. can be used.

The reticulated visco-elastic foam layer 1210 atop the bottom layer 1212can provide an additional degree of ventilation and/or heat dissipationon the top surface 1216 of the top layer 1210, can help dissipate heatwithin the body support 1202, and can therefore help to reduce heat inone or more locations of the body support 1202.

Like the top layer 1210 of the body support 1202, the bottom layer 1212can have a density providing a relatively high degree of materialdurability. Also, the density of the foam in the bottom layer 1212 canalso impact other characteristics of the foam, such as the manner inwhich the bottom layer 1212 responds to pressure, and the feel of thefoam. In some embodiments, the bottom layer 1212 has a density of noless than about 20 kg/m³ and no greater than about 80 kg/m³. In otherembodiments, a bottom layer 1212 having a density of at least about 25kg/m³ and no greater than about 60 kg/m³ is utilized. In still otherembodiments, a bottom layer 1212 having a density of at least about 30kg/m ³ and no greater than about 40 kg/m³ is utilized.

The body support 1202 illustrated in FIGS. 12 and 12A can have a bottomlayer 1212 that is at least as thick as the top layer 1210, therebyproviding a significant degree of support for the top layer 1210. Insome embodiments, the bottom layer 1212 is at least 2 times as thick asthe top layer 1210. In other embodiments, the bottom layer 1212 is atleast 3 times as thick as the top layer 1210.

The body support 1202 illustrated in FIGS. 12 and 12A is a mattress,mattress topper, overlay, or futon, and is illustrated in such form byway of example only. It will be appreciated that the features of thebody support 1202 described above are applicable to any other type ofbody support having any size and shape.

FIG. 13 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIGS. 12 and 12A.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIGS. 12 and 12A. Reference should be made tothe description above in connection with FIGS. 12 and 12A for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIG. 13 and described below. Structure and features ofthe embodiment shown in FIG. 13 that correspond to structure andfeatures of the embodiment of FIGS. 12 and 12A are designatedhereinafter in the 1300 series of reference numbers.

The body support 1302 illustrated in FIG. 13 has a top layer 1310comprising reticulated visco-elastic foam and a bottom layer 1312comprising reticulated non-visco-elastic foam. The reticulatedvisco-elastic foam (including the material properties thereof) of thetop layer 1310 is described in greater detail above in connection withthe embodiments of FIGS. 12 and 12A. The reticulated non-visco-elasticfoam of the bottom layer 1312 comprises an essentially skeletalstructure of cells in which many (if not substantially all) of the cellwalls separating one cell from another do not exist. In other words, thecells are defined by a plurality of supports or “windows” and by no cellwalls, substantially no cell walls, or by a substantially reduced numberof cell walls. In some embodiments, the foam is considered “reticulated”if at least 50% of the walls defining the cells of the foam do not exist(i.e., have been removed or were never allowed to form during themanufacturing process of the foam). Due at least in part to the skeletalcellular structure of the reticulated non-visco-elastic foam in thebottom layer 1312, the bottom layer 1312 can reduce heat in one or moreareas of the top layer 1310.

In some embodiments, it is desirable that the bottom layer 1312 ofreticulated non-visco-elastic foam be capable of providing some degreeof support that is substantially independent of temperatures experiencedby the top layer 1310 when supporting a user's body (i.e., independentof a user's body heat). Therefore, the bottom layer 1312 can comprisereticulated non-visco-elastic foam that is substantially insensitive totemperature changes (as defined above) within a range of between about15° C. and about 30° C. In some embodiments, the bottom layer 1312 cancomprise foam that is substantially insensitive to temperature changeswithin a range of between about 15° C. and about 25° C.

By virtue of the skeletal cellular structure of the bottom layer 1312illustrated in FIGS. 13, heat in the top layer 1310 of reticulatedvisco-elastic foam can be transferred away from the top layer 1310toward the bottom layer 1314 (in addition to lateral transfer of heatwithin the top layer 1310 and transfer of heat from exterior surfaces ofthe top layer 1310 by virtue of the reticulated visco-elastic foam ofthe top layer 1310). Such heat transfer can help to prevent the toplayer 1310 from reaching an undesirably high temperature. Also, thereticulated nature of the foam in the bottom layer 1312 can enablesignificantly higher airflow into, out of, and through the bottom layer1312—a characteristic of the bottom layer 1312 that can supplement theventilation provided by the reticulated visco-elastic foam of the toplayer 1310.

Like the top layer 1310, the bottom layer 1312 can have a densityproviding a relatively high degree of material durability. Also, thedensity of the foam in the bottom layer 1312 can also impact othercharacteristics of the foam, such as the manner in which the bottomlayer 1312 responds to pressure, and the feel of the foam. In someembodiments, the bottom layer 1312 has a density of no less than about20 kg/m³ and no greater than about 80 kg/m³. In other embodiments, abottom layer 1312 having a density of at least about 25 kg/m³ and nogreater than about 60 kg/m³ is utilized. In still other embodiments, abottom layer 1312 having a density of at least about 30 kg/m³ and nogreater than about 40 kg/m³ is utilized.

Also, in some embodiments, the bottom layer 1312 has a hardness of atleast about 50 N and no greater than about 300 N. In other embodiments,a bottom layer 1312 having a hardness of at least about 80 N and nogreater than about 250 N is utilized. In still other embodiments, abottom layer 1312 having a hardness of at least about 90 N and nogreater than about 180 N is utilized.

The body support 1302 illustrated in FIGS. 1-1B can have a bottom layer1312 that is at least as thick as the top layer 1310, thereby providinga significant ventilation and/or heat dissipation layer that, in someembodiments, is relatively temperature insensitive. In some embodiments,the bottom layer 1312 is at least half as thick as the top layer 1310.In other embodiments, the bottom layer 1312 is at least as thick as thetop layer 1310. In still other embodiments, the bottom layer 1312 is atleast twice as thick as the top layer 1310.

As described above with reference to the body support 1202 illustratedin FIGS. 12 and 12A, the reticulated visco-elastic foam of the top layer1310 can provide an increased amount of ventilation for the top layer1310, can help to dissipate heat within the top layer 1310, and canprovide desirable body-conforming, softness, and pressure responsivenessfor user comfort. As also described above, in some embodiments, thereticulated non-visco-elastic foam of the bottom layer 1312 can provideadditional ventilation and heat dissipation for the top layer 1310.These features can be particularly beneficial for those areas of the toplayer 1310 that have been compressed or otherwise modified in shape by auser's body. With respect to some embodiments of the present invention,the temperature insensitivity of the reticulated non-visco-elastic foamof the bottom layer 1312 can enable the bottom layer 1312 to resist formand shape change resulting from body heat from the top layer 1310, whilethe reticulated cellular structure of the bottom layer 1312 providesdesirable heat dissipation and ventilation properties for the top layer1310.

FIG. 14 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 13. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 13. Reference should be made to the descriptionabove in connection with FIG. 13 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 14 and describedbelow. Structure and features of the embodiment shown in FIG. 14 thatcorrespond to structure and features of the embodiment of FIG. 13 aredesignated hereinafter in the 1400 series of reference numbers.

Like the embodiment illustrated in FIG. 13, the body support 1402illustrated in FIG. 14 has a top layer 1410 comprising reticulatedvisco-elastic foam and an underlying layer 1412 comprising reticulatednon-visco-elastic foam. In some embodiments, the body support 1402 cantherefore provide the desirable softness, body-conforming, ventilation,and heat dissipative properties described above. The body support 1402illustrated in FIG. 14 further comprises a bottom layer 1414 beneath thelayer of reticulated non-visco-elastic foam 1412. Therefore, the layer1412 of reticulated non-visco-elastic foam is a middle layer 1412located between the top and bottom layers 1410, 1414 of the body support1402.

The bottom layer 1414 of the body support 1402 illustrated in FIG. 14comprises a cellular structure of flexible polyurethane foam that isrelatively highly resilient and supportive. This relatively highlyresilient flexible cellular foam is described in greater detail above inconnection with the embodiment of FIGS. 12 and 12A. In some embodiments,the bottom layer 1414 comprising the relatively highly resilientflexible cellular foam is a supportive layer providing a relativelystiff substrate upon which the top and middle layers 1410, 1412 lie, andhas a degree of deformability to provide user comfort (to the extentthat the user's weight affects the shape of the bottom layer 1414).Therefore, the bottom layer 1414 can comprise a foam having a relativelyhigh resilience capable of providing significant support to the top andmiddle layers 1410, 1412. The bottom layer 1414 can have a resiliencegreater than that of the top and middle layers 1410, 1412.

The body support 1402 illustrated in FIG. 14 can have a bottom layer1414 that is at least as thick as the combination of the top and middlelayers 1410, 1412, thereby providing substantial support for the top andmiddle layers 1410, 1412. In some embodiments, the bottom layer 1414 isat least 0.22 times as thick as the combination of the top and middlelayers 1410, 1412. In other embodiments, the bottom layer 1414 is atleast 0.40 times as thick as the combination of the top and middlelayers 1410, 1412.

FIG. 15 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 14. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 14. Reference should be made to the descriptionabove in connection with FIG. 14 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 15 and describedbelow. Structure and features of the embodiment shown in FIG. 15 thatcorrespond to structure and features of the embodiment of FIG. 14 aredesignated hereinafter in the 1500 series of reference numbers.

Like the body support 1402 illustrated in FIG. 14, the body support 1502illustrated in FIG. 15 has a top layer 1510 comprising reticulatedvisco-elastic foam, beneath which lies middle and bottom layers 1512,1514 of the body support 1502. However, the materials of the middle andbottom layers 1512, 1514 are switched compared to the body support 1402illustrated in FIG. 14. Accordingly, the middle layer 1512 of the bodysupport 1502 illustrated in FIG. 15 comprises a relatively highlyresilient flexible cellular foam, and the bottom layer 1514 of the bodysupport 1502 comprises reticulated non-visco-elastic foam. Therelatively highly resilient flexible cellular foam and the reticulatednon-visco-elastic foam of the middle and bottom layers 1512, 1514,respectively, are described in greater detail above in connection withthe embodiment illustrated in FIG. 14 (incorporating information inconnection with the embodiments illustrated in FIGS. 12-13).

In the embodiment illustrated in FIG. 15, the reticulated visco-elasticfoam of the first layer 1510 can be provided with a desired degree ofsupport by the adjacent underlying layer of relatively highly resilientflexible cellular foam, rather than by a layer of such materialunderlying another intermediate layer as shown in FIG. 14. Also withreference to FIG. 15, the middle layer 1512 can provide enhanced usersupport, depending at least in part upon the thicknesses of the top andmiddle layers 1510, 1512. The top layer 1510 of reticulatedvisco-elastic foam and the bottom layer 1514 of reticulatednon-visco-elastic foam can reduce heat in the middle layer 1512, drawingheat from both sides of the middle layer 1512 and/or providing enhancedventilation of the body support 1502 on both sides of the middle layer1512 (due at least in part to the reticulated cellular structure of thefoam in the top and bottom layers 1510, 1512).

The body support 1502 illustrated in FIG. 15 can have a middle layer1512 that is at least 0.33 times at least as thick as the top layer 1510to provide a desirable degree of support for the top layer 1510. In someembodiments, the middle layer 1512 can be at least half as thick as thetop layer 1510 for this purpose. In other embodiments, a middle layer1512 that is at least as thick as the top layer 1510 is used for thispurpose.

With further reference to FIG. 15, the body support 1502 can have abottom layer 1514 that is at least 0.15 times as thick as the combinedthickness of the top and middle layers 1510, 1512 to carry heat awayfrom the middle layer 1512. In some embodiments, the bottom layer 1514can be at least 0.25 times as thick as the combined thickness of the topand middle layers 1510, 1512 for this purpose. In other embodiments, abottom layer 1514 that is at least 0.36 times as thick as the combinedthickness of the top and middle layers 1510, 1512 is used for thispurpose.

A body support 1602 according to another embodiment of the presentinvention is illustrated in FIG. 16, and comprises two layers ofmaterial: a top layer 1610 comprising reticulated visco-elastic foam,and a bottom layer 1612 comprising open-celled non-reticulatedvisco-elastic foam.

The reticulated visco-elastic foam in the top layer 1610 (including thematerial properties of the reticulated visco-elastic foam) is describedin greater detail above in connection with the embodiments of FIGS. 12and 12A. The open-celled non-reticulated visco-elastic foam in thebottom layer 1612 falls generally within the category of foams otherwiseknown as “memory foams” or “low resilience foams”.

In some embodiments, the bottom layer 1612 has a relatively lowhardness, providing a deformable and comfortable substrate beneath thetop layer 1610 of reticulated visco-elastic foam. Depending at least inpart upon the thickness of the top layer 1610, the bottom layer 1612 canconform to a user's body based upon pressure exerted by the user's body,thereby supplementing the ability of the top layer 1610 to distributeforce applied by the user's body upon the body support 1602. In someembodiments, the bottom layer 1612 has a hardness of at least about 30 Nand no greater than about 175 N. In other embodiments, a bottom layer1612 having a hardness of at least about 40 N and no greater than about110 N is utilized. In still other embodiments, a bottom layer 1612having a hardness of at least about 40 N and no greater than about 75 Nis utilized.

The bottom layer 1612 can also have a density providing a relativelyhigh degree of material durability. Also, the density of the foam in thebottom layer 1612 can impact other characteristics of the foam, such asthe manner in which the bottom layer 1612 responds to pressure, and thefeel of the foam. In some embodiments, the bottom layer 1612 has adensity of no less than about 30 kg/m³ and no greater than about 150kg/m³. In other embodiments, a bottom layer 1612 having a density of atleast about 40 kg/m³ and no greater than about 125 kg/m³ is utilized. Instill other embodiments, a bottom layer 1612 having a density of atleast about 60 kg/m³ and no greater than about 115 kg/m³ is utilized.

The non-reticulated visco-elastic material of the bottom layer 1612 canbe selected for responsiveness to any range of temperatures. However, insome embodiments, a temperature responsiveness in a range of a user'sbody temperatures (or in a range of temperatures to which the bottomlayer 1612 is exposed by a user's body upon the body support 1602) canprovide significant advantages. In some embodiments, a non-reticulatedvisco-elastic material selected for the bottom layer 1612 can beresponsive to temperature changes above at least 0° C. In otherembodiments, the non-reticulated visco-elastic material selected for thebottom layer 1612 can be responsive to temperature changes within arange of at least about 10° C. In still other embodiments, thenon-reticulated visco-elastic material selected for the bottom layer1612 can be responsive to temperature changes within a range of at leastabout 15° C.

In some embodiments, the top layer 1610 of reticulated visco-elasticfoam can reduce the amount of heat in the bottom layer 1612 (due atleast in part to the reticulated cellular structure of the foam in thetop layer 1612) while still providing a relatively soft and comfortablesurface of the body support 1602, and the capability to conform to auser's body and/or distribute pressure responsive to force from the user(by virtue of the visco-elastic nature of the top layer 1610).

The body support 1602 illustrated in FIG. 16 can have a top layer 1610that is between 0.33 and 2 times the thickness of the bottom layer 1612,thereby providing a significant degree of ventilation and/or heatdissipation via the top layer 1610 and the desirable body-conforming,pressure distribution, and comfort characteristics of the bottom layer1612. In some embodiments, the body support 1602 has a top layer 1610that is between 0.5 and 1.5 times the thickness of the bottom layer 1612for these purposes. In still other embodiments, the body support 1602has a top layer 1610 that is about the same thickness of the bottomlayer 1612 for these purposes.

FIG. 17 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 16. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 16. Reference should be made to the descriptionabove in connection with FIG. 16 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 17 and describedbelow. Structure and features of the embodiment shown in FIG. 17 thatcorrespond to structure and features of the embodiment of FIG. 16 aredesignated hereinafter in the 1700 series of reference numbers.

Like the body support 1602 illustrated in FIG. 16, the body support 1702illustrated in FIG. 17 has a top layer 1710 comprising reticulatedvisco-elastic foam and an underlying layer 1712 comprising open-cellednon-reticulated visco-elastic foam. In some embodiments, the bodysupport 1702 can therefore provide the desirable softness,body-conforming, ventilation, and heat transfer properties describedabove in connection with the embodiment of FIG. 16. The body support1702 illustrated in FIG. 17 further comprises a bottom layer 1714beneath the layer of non-reticulated visco-elastic foam 1712. Therefore,the layer 1712 of non-reticulated visco-elastic foam is a middle layer1712 located between the top and bottom layers 1710, 1714 of the bodysupport 1702.

The bottom layer 1714 of the body support 1702 illustrated in FIG. 17comprises reticulated non-visco-elastic foam. The reticulatednon-visco-elastic foam (and various possible properties thereof) of thebottom layer 1714 is described in greater detail above in connectionwith the embodiment of FIG. 13.

In some embodiments, the top layer 1710 of reticulated visco-elasticfoam and the bottom layer 1714 of reticulated non-visco-elastic foam canreduce the amount of heat in the middle layer 1712, drawing heat fromboth sides of the middle layer 1712 and/or providing enhancedventilation of the body support 1702 on both sides of the middle layer1712 due at least in part to the reticulated cellular structure of thefoam in the top and bottom layers 1710, 1714. In addition, thevisco-elastic nature of the top layer 1710 can still provide arelatively soft and comfortable surface of the body support 1702, theability to conform to a user's body responsive to pressure from theuser's body, and a degree of pressure distribution for the user's body.

The body support 1702 illustrated in FIG. 17 can have a bottom layer1714 that is at least 0.17 times at least as thick as the combinedthickness of the top and middle layers 1710, 1712 to provide a desirabledegree of heat dissipation and ventilation from the bottom of the middlelayer 1712. In some embodiments, the bottom layer 1714 can be at least0.25 times as thick as the combined thickness of the top and middlelayers 1710, 1712 for these purposes. In still other embodiments, abottom layer 1714 that is at least 0.375 times as thick as the combinedthickness of the top and middle layers 1710, 1712 is used for thesepurposes.

FIG. 18 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 16. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 16. Reference should be made to the descriptionabove in connection with FIG. 16 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 18 and describedbelow. Structure and features of the embodiment shown in FIG. 18 thatcorrespond to structure and features of the embodiment of FIG. 16 aredesignated hereinafter in the 1800 series of reference numbers.

Like the body support 1602 illustrated in FIG. 16, the body support 1802illustrated in FIG. 18 has a top layer 1810 comprising reticulatedvisco-elastic foam and an underlying layer 1812 comprising open-cellednon-reticulated visco-elastic foam. In some embodiments, the bodysupport 1802 can therefore provide the desirable softness,body-conforming, ventilation, and heat transfer properties describedabove in connection with the embodiment of FIG. 16. The body support1802 illustrated in FIG. 18 further comprises a bottom layer 1814beneath the layer of non-reticulated visco-elastic foam 1812. Therefore,the layer 1812 of non-reticulated visco-elastic foam is a middle layer1812 located between the top and bottom layers 1810, 1814 of the bodysupport 1802.

The bottom layer 1814 of the body support 1802 illustrated in FIG. 18comprises a cellular structure of flexible polyurethane foam that isrelatively highly resilient and supportive. This relatively highlyresilient flexible cellular foam (and various possible propertiesthereof) is described in greater detail above in connection with theembodiment of FIGS. 12 and 12A.

In some embodiments, the bottom layer 1814 is a supportive layerproviding a relatively stiff substrate upon which the top and middlelayers 1810, 1812 lie, while still providing a degree of deformabilityfor user comfort (to the extent that the user's weight affects the shapeof the bottom layer 1814). Therefore, the bottom layer 1814 can comprisea foam having a relatively high resilience capable of providingsignificant support to the top and middle layers 1810, 1812. Both of thetop and middle layers 1810, 1812 can provide the desirablebody-conforming and pressure distribution features described above,while the top layer 1810 can provide significant heat dissipation andventilation for the body support 1802 as also described above. In someembodiments, the bottom layer 1814 has a resilience greater than that ofthe top and middle layers 1810, 1812.

The body support 1802 illustrated in FIG. 18 can have a bottom layer1814 that is at least 0.17 times as thick as the combined thickness ofthe top and middle layers 1810, 1812, thereby providing substantialsupport for the top and middle layers 1810, 1812. In some embodiments,the bottom layer 1814 is at least 0.33 times as thick as the combinedthickness of the top and middle layers 1810, 1812. In other embodiments,the bottom layer 1814 is at least half as thick as the combinedthickness of the top and middle layers 1810, 1812.

A body support 1902 according to another embodiment of the presentinvention is illustrated in FIG. 19, and comprises two layers ofmaterial: a top layer 1910 comprising open-celled non-reticulatedvisco-elastic foam, and a bottom layer 1912 comprising reticulatedvisco-elastic foam. The non-reticulated visco-elastic foam (and variouspossible properties thereof) is described above in connection with theembodiment of FIG. 16. The reticulated visco-elastic foam (and variouspossible properties thereof) is described above in connection with theembodiment of FIGS. 12 and 12A.

In some embodiments, heat received by the top layer 1910 (e.g., from auser resting upon the body support 1902) can be dissipated by thereticulated visco-elastic foam of the bottom layer 1912 due at least inpart to the reticulated cellular structure of the foam in the bottomlayer 1912. In this body support construction, the softness,body-conforming, and pressure-distributing properties of thenon-reticulated visco-elastic foam are retained in the top layer 1910(proximate the body of a user) while the ventilating andheat-dissipative properties of the bottom layer 1912 can help reduceheat in the top layer 1910. The bottom layer 1912 can also providesoftness, can at least partially conform to a user's body responsive topressure from the user's body, and can distribute pressure of the user'sbody by virtue of the visco-elastic nature of the bottom layer 1912.

The body support 1902 illustrated in FIG. 19 can have a bottom layer1912 that is at least 0.33 times the thickness of the top layer 1910,thereby providing a significant degree of ventilation and/or heatdissipation via the bottom layer 1912 and the desirable body-conforming,pressure distribution, and comfort properties of the top layer 1910. Insome embodiments, the body support 1902 has a bottom layer 1912 that isat least as thick as the top layer 1910 for these purposes. In stillother embodiments, the body support 1902 has a bottom layer 1912 that isat least twice as thick as the top layer 1910 for these purposes.

FIG. 20 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 19. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 19. Reference should be made to the descriptionabove in connection with FIG. 19 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 20 and describedbelow. Structure and features of the embodiment shown in FIG. 20 thatcorrespond to structure and features of the embodiment of FIG. 19 aredesignated hereinafter in the 2000 series of reference numbers.

Like the embodiment illustrated in FIG. 19, the body support 2002illustrated in FIG. 20 has a top layer 2010 comprising open-cellednon-reticulated visco-elastic foam, and an underlying layer 2012comprising reticulated visco-elastic foam. In some embodiments, the bodysupport 2002 can therefore provide the softness, body-conforming, andpressure-distributing characteristics of the non-reticulatedvisco-elastic foam in the top layer 2010 (proximate the body of a user)as described above, and the ventilating and heat-dissipative propertiesof the underlying layer 2012 for dissipating heat from the top layer2010 as also described above. The underlying layer 2012 can also providesoftness of the body support 2002, can help to conform the body support2002 to the user's body, and can thereby distribute pressure of theuser's body by virtue of the visco-elastic property of the underlyinglayer 2012.

The body support 2002 illustrated in FIG. 20 further comprises a bottomlayer 2014 beneath the layer of reticulated visco-elastic foam 2012.Therefore, the layer 2012 of reticulated visco-elastic foam is a middlelayer 2012 located between the top and bottom layers 2010, 2014 of thebody support 2002.

The bottom layer 2014 of the body support 2002 illustrated in FIG. 20comprises open-celled non-reticulated visco-elastic foam. Thenon-reticulated visco-elastic foam (and various possible propertiesthereof) of the bottom layer 2014 is described above with reference tothe top layer 2010 of the body support 2002. Also, the non-reticulatedvisco-elastic foam of the bottom layer 2014 can have substantially thesame or different properties than the non-reticulated visco-elastic foamof the top layer 2010, while still falling within the material propertyranges of the non-reticulated visco-elastic foam described above. Insome embodiments, top and bottom layers 2010, 2014 of non-reticulatedvisco-elastic foam can be utilized in products that can be oriented witheither layer 2010, 2014 facing generally toward a user's body (e.g., amattress that can be flipped on either side). Also or alternatively, thenon-reticulated visco-elastic foam of the bottom layer 2014 cansupplement the body-conforming and pressure-distributing capabilities ofthe top and middle layers 2010, 2012 described above.

The body support 2002 illustrated in FIG. 20 is also an example of themanner in which a layer of non-reticulated visco-elastic foam can bereplaced by two layers of non-reticulated visco-elastic foam flanking alayer of reticulated visco-elastic foam for ventilation and heatdissipation.

FIG. 21 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 19. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 19. Reference should be made to the descriptionabove in connection with FIG. 19 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 21 and describedbelow. Structure and features of the embodiment shown in FIG. 21 thatcorrespond to structure and features of the embodiment of FIG. 19 aredesignated hereinafter in the 2100 series of reference numbers.

Like the embodiment illustrated in FIG. 19, the body support 2102illustrated in FIG. 21 has a top layer 2110 comprising open-cellednon-reticulated visco-elastic foam, and an underlying layer 2112comprising reticulated visco-elastic foam. In some embodiments, the bodysupport 2102 can therefore provide the softness, body-conforming, andpressure-distributing characteristics of the non-reticulatedvisco-elastic foam in the top layer 2110 (proximate the body of a user)as described above, and the ventilating and heat-dissipative propertiesof the underlying layer 2112 for reducing heat in the top layer 2110 asalso described above. The underlying layer 2112 can also providesoftness for the body support 2002, can help to conform the body support2102 to the user's body, and can thereby distribute pressure of theuser's body by virtue of the visco-elastic property of the underlyinglayer 2112.

The body support 2102 illustrated in FIG. 21 further comprises a bottomlayer 2114 beneath the layer of reticulated visco-elastic foam 2112.Therefore, the layer 2112 of reticulated visco-elastic foam is a middlelayer 2112 located between the top and bottom layers 2110, 2114 of thebody support 2102.

The bottom layer 2114 of the body support 2102 illustrated in FIG. 21comprises reticulated non-visco-elastic foam. The reticulatednon-visco-elastic foam (and various possible properties thereof) of thebottom layer 2114 is described in greater detail above in connectionwith the embodiment of FIG. 13.

In some embodiments, the middle layer 2112 of reticulated visco-elasticfoam can reduce heat in the top layer 2110 as described above. However,some types of reticulated visco-elastic foam that can be utilized in themiddle layer 2112 do not provide a high degree of support for the bodysupport 2102. While this may be acceptable and/or desirable in someapplications (e.g., in pillows, futons, and the like), in someembodiments additional support is desired. The reticulatednon-visco-elastic foam of the bottom layer 2114 can provide suchadditional support, while still providing the ventilation and/or heatdissipation properties described earlier in connection with theembodiment of FIG. 13. A bottom layer 2114 of reticulatednon-visco-elastic foam can be utilized for other reasons as well,including without limitation to provide a layer of material that is lessresponsive or substantially non-responsive to a user's body temperature(described in greater detail above in connection with the embodiment ofFIG. 13), while still providing the ventilation and/or heat dissipationproperties also described above.

The body support 2102 illustrated in FIG. 21 can have a bottom layer2114 that is at least as thick as the combined thicknesses of the topand middle layers 2110, 2112, thereby providing substantial support,ventilation, and heat dissipation for the top and middle layers 2110,2112. In some embodiments, the bottom layer 2114 is at least 0.17 timesas thick as the combined thickness of the top and middle layers 2110,2112. In other embodiments, the bottom layer 2114 is at least 0.375times as thick as the combined thickness of the top and middle layers2110, 2112.

FIG. 22 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 19. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 19. Reference should be made to the descriptionabove in connection with FIG. 19 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 22 and describedbelow. Structure and features of the embodiment shown in FIG. 22 thatcorrespond to structure and features of the embodiment of FIG. 19 aredesignated hereinafter in the 2200 series of reference numbers.

Like the embodiment illustrated in FIG. 19, the body support 2202illustrated in FIG. 22 has a top layer 2210 comprising open-cellednon-reticulated visco-elastic foam, and an underlying layer 2212comprising reticulated visco-elastic foam. In some embodiments, the bodysupport 2202 can therefore provide the softness, body-conforming, andpressure-distributing characteristics of the non-reticulatedvisco-elastic foam in the top layer 2210 (proximate the body of a user)as described above, and the ventilating and heat-dissipative propertiesof the underlying layer 2212 for reducing heat in the top layer 2210 asalso described above. The underlying layer 2212 can also providesoftness to the body support 2202, can help to conform the body support2202 to the user's body, and can thereby distribute pressure of theuser's body by virtue of the visco-elastic property of the underlyinglayer 2212.

The body support 2202 illustrated in FIG. 22 further comprises a bottomlayer 2214 beneath the layer of reticulated visco-elastic foam 2212.Therefore, the layer 2212 of reticulated visco-elastic foam is a middlelayer 2212 located between the top and bottom layers 2210, 2214 of thebody support 2202.

The bottom layer 2214 of the body support 2202 illustrated in FIG. 22comprises a cellular structure of flexible polyurethane foam that isrelatively highly resilient and supportive. The bottom layer 2214 cantherefore provide a relatively stiff substrate upon which the top andmiddle layers 2210, 2212 lie, thereby providing support for the top andmiddle layers 2210, 2212. Also, the flexibility of the bottom layer 2214can provide a degree of deformability for user comfort (to the extentthat the user's weight affects the shape of the bottom layer 2214),while the top and middle layers 2210, 2212 provide the desirablebody-conforming and pressure distribution features described above, andwhile the middle layer 2212 provides significant heat dissipation andventilation for the body support 2202. In some embodiments, the bottomlayer 2214 has a resilience greater than that of the top and middlelayers 2210, 2212.

The body support 2202 illustrated in FIG. 22 can have a bottom layer2214 that is at least as thick as the combined thicknesses of the topand middle layers 2210, 2212, thereby providing substantial support forthe top and middle layers 2210, 2212. In some embodiments, the bottomlayer 2214 is at least 0.17 times as thick as the combined thicknessesof the top and middle layers 2210, 2212. Also, in some embodiments, thebottom layer 2214 is at least half as thick as the combined thicknessesof the top and middle layers 2210, 2212.

FIG. 23 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIGS. 12 and 12A.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIGS. 12 and 12A. Reference should be made tothe description above in connection with FIGS. 12 and 12A for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIG. 23 and described below. Structure and features ofthe embodiment shown in FIG. 23 that correspond to structure andfeatures of the embodiment of FIGS. 12 and 12A are designatedhereinafter in the 2300 series of reference numbers.

Like the body support 1202 illustrated in FIGS. 12 and 12A, the bodysupport 2302 illustrated in FIG. 23 has a top layer 2310 comprisingreticulated visco-elastic foam, beneath which lies a bottom layer 2312comprising a cellular structure of relatively resilient flexiblepolyurethane material. The reticulated visco-elastic foam and therelatively highly resilient flexible cellular foam of the top and bottomlayers 2310, 2312, respectively, are described in greater detail abovein connection with the embodiment illustrated in FIGS. 12 and 12A.

The top surface 2320 of the bottom layer 2312 of the body support 2302has a non-planar shape beneath the substantially planar bottom surface2318 of the top layer 2310. The non-planar shape of the top surface 2320can take any of the forms described above in connection with thenon-planar top surface 420 of the bottom layer 412 in the body support402 illustrated in FIG. 4, and can be defined by a plurality ofprotrusions 2328 and/or a plurality of apertures (not shown) as alsodescribed above. Passages 2330 between the substantially planar bottomsurface 2318 of the top layer 2310 and the non-planar top surface 2320of the bottom layer 2312 can provide a degree of ventilation andenhanced heat dissipation of the body support 2302. In otherembodiments, such passages 2330 can be defined between a non-planarbottom surface 2318 of the top layer 2310 and a substantially planar topsurface 2320 of the bottom layer 2312, or between a non-planar bottomsurface 2318 of the top layer 2310 and a non-planar top surface 2320 ofthe bottom layer 2312, wherein the non-planar surface(s) can be definedin any of the manners described above in connection with the illustratedembodiment of FIG. 4.

Passages 2330 running between the top and bottom layers 2310, 2312illustrated in FIG. 23 can supplement the ventilation and/or heatdissipative capabilities of the top layer 2310 of reticulatedvisco-elastic foam, and can reduce heat in the bottom layer 2312 ofrelatively highly resilient flexible cellular foam. In this regard, theskeletal structure of the cells in the top layer 2310 of reticulatedvisco-elastic foam can enable heat to be transferred from the top layer2310 to and through the passages 2330.

FIG. 24 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 14. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 14. Reference should be made to the descriptionabove in connection with FIG. 14 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 24 and describedbelow. Structure and features of the embodiment shown in FIG. 24 thatcorrespond to structure and features of the embodiment of FIG. 14 aredesignated hereinafter in the 2400 series of reference numbers.

As described in greater detail above with regard to the body support1402 illustrated in FIG. 14, the body support 2402 illustrated in FIG.24 comprises a top layer 2410 comprising reticulated visco-elastic foam,a middle layer 2412 comprising reticulated non-visco-elastic foam, and abottom layer 2414 comprising a cellular structure of relativelyresilient flexible polyurethane material. The reticulated visco-elasticfoam and the relatively highly resilient flexible cellular foam of thetop and bottom layers 2410, 2414, respectively, are described in greaterdetail above in connection with the embodiment illustrated in FIGS. 12and 12A. The reticulated non-visco-elastic foam of the middle layer 2412is described in greater detail above in connection with the embodimentillustrated in FIG. 13.

The top surface 2424 of the bottom layer 2414 has a non-planar shapebeneath the substantially planar bottom surface 2422 of the middle layer2412. The non-planar shape of the top surface 2424 can take any of theforms described above in connection with the non-planar top surface 420of the bottom layer 412 in the body support 402 illustrated in FIG. 4,and can be defined by a plurality of protrusions 2428 and/or a pluralityof apertures (not shown) as also described above. Passages 2430 betweenthe substantially planar bottom surface 2422 of the middle layer 2412and the non-planar top surface 2424 of the bottom layer 2414 can providea degree of ventilation and enhanced heat dissipation of the bodysupport 2402 (e.g., moving heat from the middle layer 2412, and in somecases from both the middle and top layers 2412, 2410). In otherembodiments, such passages 2430 can be defined between a non-planarbottom surface 2422 of the middle layer 2412 and a substantially planartop surface 2424 of the bottom layer 2414, or between a non-planarbottom surface 2422 of the middle layer 2412 and a non-planar topsurface 2424 of the bottom layer 2414, wherein the non-planar surface(s)can be defined in any of the manners described above in connection withthe illustrated embodiment of FIG. 4.

Passages 2430 running between the middle and bottom layers 2412, 2414illustrated in FIG. 24 can provide the body support 2402 with increasedcapacity to dissipate heat from the middle layer 2412 of reticulatednon-visco-elastic foam, which can receive a user's body heat from thetop layer 2410 of reticulated visco-elastic foam. The skeletal structureof the cells in the top and middle layers 2410, 2412 can enable heat tobe transferred from the top and middle layers 2410, 2412 to and throughthe passages 2430. Although heat transfer in lateral directions (i.e.,toward the edges of the body support 2402) still occurs in the top andmiddle layers 2410, 2412 of reticulated visco-elastic and reticulatednon-visco-elastic foam based at least in part upon the cell structure ofsuch foams, the passages 2430 can enhance this heat transfer.

FIG. 25 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 21. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 21. Reference should be made to the descriptionabove in connection with FIG. 21 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 25 and describedbelow. Structure and features of the embodiment shown in FIG. 25 thatcorrespond to structure and features of the embodiment of FIG. 21 aredesignated hereinafter in the 2500 series of reference numbers.

As described in greater detail above with regard to the body support2102 illustrated in FIG. 21, the body support 2502 illustrated in FIG.25 comprises a top layer 2510 comprising open-celled non-reticulatedvisco-elastic foam, a middle layer 2512 comprising reticulatedvisco-elastic foam, and a bottom layer 2514 comprising reticulatednon-visco-elastic foam.

The top surface 2520 of the middle layer 2512 has a non-planar shapebeneath the substantially planar bottom surface 2518 of the top layer2510. The non-planar shape of the top surface 2520 of the middle layer2512 can take any of the forms described above in connection with thenon-planar top surface 420 of the bottom layer 412 in the body support402 illustrated in FIG. 4, and can be defined by a plurality ofprotrusions 2528 and/or a plurality of apertures (not shown) as alsodescribed above. Passages 2530 between the substantially planar bottomsurface 2518 of the top layer 2510 and the non-planar top surface 2520of the middle layer 2512 can provide a degree of ventilation andenhanced heat dissipation of the body support 2502. In some embodiments,the passages 2530 can be defined between a non-planar bottom surface2518 of the top layer 2510 and a substantially planar top surface 2520of the middle layer 2512, or between a non-planar bottom surface 2518 ofthe top layer 2510 and a non-planar top surface 2520 of the middle layer2512, wherein the non-planar surface(s) can be defined in any of themanners described above in connection with the illustrated embodiment ofFIG. 4.

The passages 2530 between the top and middle layers 2510, 2512 describedabove can be particularly useful in reducing heat in regions of the bodysupport 2502. The passages 2530 can supplement the ventilation and/orheat dissipative capabilities of the middle and bottom layers 2512, 2514of reticulated visco-elastic foam and reticulated non-visco-elasticfoam, and can reduce heat in the top layer 2510 of non-reticulatedvisco-elastic foam. In addition, the skeletal structure of the cells inthe middle and bottom layers 2512, 2514 can enable heat to betransferred from the top layer 2510 to and through the cells of themiddle and bottom layers 2512, 2514.

FIG. 26 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 22. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 22. Reference should be made to the descriptionabove in connection with FIG. 22 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 26 and describedbelow. Structure and features of the embodiment shown in FIG. 26 thatcorrespond to structure and features of the embodiment of FIG. 22 aredesignated hereinafter in the 2600 series of reference numbers.

As described in greater detail above with regard to the body support2202 illustrated in FIG. 22, the body support 2602 illustrated in FIG. 5comprises a top layer 2610 comprising open-celled non-reticulatedvisco-elastic foam, a middle layer 2612 comprising reticulatedvisco-elastic foam, and a bottom layer 2614 comprising flexible cellularpolyurethane foam having a relatively high resilience. However, the topsurface 2624 of the bottom layer 2614 has a non-planar shape beneath thesubstantially planar bottom surface 2622 of the middle layer 2612. Thenon-planar shape of the top surface 2624 can take any of the formsdescribed above in connection with the non-planar top surface 420 of thebottom layer 412 in the body support 402 illustrated in FIG. 4, and canbe defined by a plurality of protrusions 2628 and/or a plurality ofapertures (not shown) as also described above. Passages 2630 can bedefined between the substantially planar bottom surface 2622 of themiddle layer 2612 and the non-planar top surface 2624 of the bottomlayer 2614. In other embodiments, such passages 2630 can be definedbetween a non-planar bottom surface 2622 of the middle layer 2612 and asubstantially planar top surface 2624 of the bottom layer 2614, orbetween a non-planar bottom surface 2622 of the middle layer 2612 and anon-planar top surface 2624 of the bottom layer 2614, wherein thenon-planar surface(s) can be defined in any of the manners describedabove in connection with the illustrated embodiment of FIG. 4.

Passages 2630 running between the middle and bottom layers 2612, 2614illustrated in FIG. 26 can provide a degree of ventilation and enhancedheat dissipation of the body support 2602 (e.g., in which heat can movefrom the middle layer 2612 toward the passages 2630, and in some casesfrom both the middle and top layers 2612, 2610 toward the passages2630). The skeletal structure of the cells in the middle layer 2612 canenable heat to be transferred from the top layer 2610 to and through thepassages 2630. Although heat transfer in lateral directions. (i.e.,toward the edges of the body support 2602) still occurs in the middlelayer 2612 of reticulated visco-elastic foam based at least in part uponthe cell structure of the reticulated visco-elastic foam, the passages2630 can enhance this heat transfer.

FIG. 27 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 17. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 17. Reference should be made to the descriptionabove in connection with FIG. 17 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 27 and describedbelow. Structure and features of the embodiment shown in FIG. 27 thatcorrespond to structure and features of the embodiment of FIG. 17 aredesignated hereinafter in the 2700 series of reference numbers.

As described in greater detail above with regard to the body support1702 illustrated in FIG. 17, the body support 2702 illustrated in FIG.25 comprises a top layer 2710 comprising reticulated visco-elastic foam,a middle layer 2712 comprising open-celled non-reticulated visco-elasticfoam, and a bottom layer 2714 comprising reticulated non-visco-elasticfoam.

The top surface 2720 of the middle layer 2712 has a non-planar shapebeneath the substantially planar bottom surface 2718 of the top layer2710. The non-planar shape of the top surface 2720 can take any of theforms described above in connection with the non-planar top surface 420of the bottom layer 412 in the body support 402 illustrated in FIG. 4,and can be defined by a plurality of protrusions 2728 and/or a pluralityof apertures (not shown) as also described above. Passages 2730 can bedefined between the substantially planar bottom surface 2718 of the toplayer 2710 and the non-planar top surface 2720 of the middle layer 2712.In some embodiments, the passages 2730 can be defined between anon-planar bottom surface 2718 of the top layer 2710 and a substantiallyplanar top surface 2720 of the middle layer 2712, or between anon-planar bottom surface 2718 of the top layer 2710 and a non-planartop surface 2720 of the middle layer 2712, wherein the non-planarsurface(s) can be defined in any of the manners described above inconnection with the illustrated embodiment of FIG. 4.

Passages 2730 running between the top and middle layers 2710, 2712illustrated in FIG. 27 can provide the body support 2702 with a degreeof ventilation and/or with an increased capacity to dissipate heat fromthe middle layer 2712 of non-reticulated visco-elastic foam, which canreceive a user's body heat from the top layer 2710 of reticulatedvisco-elastic foam. In some applications, heat can be transferredthrough the skeletal structure of cells in the top layer 2710 and thenthrough the passages 2730 between the top and middle layers 2710, 2712.

FIG. 28 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 18. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 18. Reference should be made to the descriptionabove in connection with FIG. 18 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 28 and describedbelow. Structure and features of the embodiment shown in FIG. 28 thatcorrespond to structure and features of the embodiment of FIG. 18 aredesignated hereinafter in the 2800 series of reference numbers.

As described in greater detail above with regard to the body support1802 illustrated in FIG. 18, the body support 2802 illustrated in FIG.28 comprises a top layer 2810 comprising reticulated visco-elastic foam,a middle layer 2812 comprising open-celled non-reticulated visco-elasticfoam, and a bottom layer 2814 comprising flexible cellular polyurethanefoam having a relatively high resilience.

The top surface 2824 of the bottom layer 2814 has a non-planar shapebeneath the substantially planar bottom surface 2822 of the middle layer2812. The non-planar shape of the top surface 2824 can take any of theforms described above in connection with the non-planar top surface 420of the bottom layer 412 in the body support 402 illustrated in FIG. 4,and can be defined by a plurality of protrusions 2828 and/or a pluralityof apertures (not shown) as also described above. Passages 2830 can bedefined between the substantially planar bottom surface 2822 of themiddle layer 2812 and the non-planar top surface 2824 of the bottomlayer 2814. In other embodiments, such passages 2830 can be definedbetween a non-planar bottom surface 2822 of the middle layer 2812 and asubstantially planar top surface 2824 of the bottom layer 2814, orbetween a non-planar bottom surface 2822 of the middle layer 2812 and anon-planar top surface 2824 of the bottom layer 2814, wherein thenon-planar surface(s) can be defined in any of the manners describedabove in connection with the illustrated embodiment of FIG. 4.

Passages 2830 running between the middle and bottom layers 2812, 2814illustrated in FIG. 28 can provide the body support 2802 with a degreeof ventilation and/or increased capacity to dissipate heat from themiddle layer 2812 of non-reticulated visco-elastic foam, which canreceive a user's body heat through the top layer 2810 of reticulatedvisco-elastic foam. In particular, the passages 2830 running beneath themiddle layer 2812 of non-reticulated visco-elastic foam can enable heatto be transferred from the middle layer 2812 through the passages 2830.

FIG. 29 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIGS. 12 and 12A.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIGS. 12 and 12A. Reference should be made tothe description above in connection with FIGS. 12 and 12A for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIG. 29 and described below. Structure and features ofthe embodiment shown in FIG. 29 that correspond to structure andfeatures of the embodiment of FIGS. 12 and 12A are designatedhereinafter in the 2900 series of reference numbers.

Like the body support 1202 illustrated in FIGS. 12 and 12A, the bodysupport 2902 illustrated in FIG. 29 has a top layer 2910 comprisingreticulated visco-elastic foam, beneath which lies a bottom layer 2912comprising flexible cellular polyurethane foam having a relatively highresilience. The reticulated visco-elastic foam and the relatively highlyresilient flexible cellular foam of the top and bottom layers 2910,2912, respectively, are described in greater detail above in connectionwith the embodiment illustrated in FIGS. 12 and 12A.

With continued reference to the body support 2902 illustrated in FIG.29, the top and bottom layers 2910, 2912 of the body support 2902 canhave a cover 2948 comprising reticulated non-visco-elastic foam. Thereticulated non-visco-elastic foam of the cover 2948 can have the sameproperties as described above with reference to the bottom layer 1312 ofthe body support 1302 illustrated in FIG. 13. Also, the reticulatednon-visco-elastic foam of the cover 2948 can cover any portion of thetop and bottom layers 2910, 2912 desired. For example, the cover 2948illustrated in FIG. 29 covers substantially the entire top surface 2916of the top layer 2910. In other embodiments, the cover 2948 can also orinstead cover any portion or all of the sides and ends of the top and/orbottom layers 2910, 2912, and/or can underlie any portion or all of thebottom surface 2924 of the bottom layer 2912. In some embodiments, thecover 2948 substantially entirely surrounds the top and bottom layers2910, 2912.

The reticulated non-visco-elastic foam cover 2948 can be selected toprovide a heightened degree of fire resistance to the body support 2902,and in some countries and/or localities can be utilized to meet firecodes calling for such fire resistance. Although other materials capableof meeting such fire code requirements can be utilized, the use ofreticulated non-visco-elastic foam can provide improved ventilation forthe surface(s) of the first and/or second layers 2910, 2912 covered bythe reticulated non-visco-elastic foam cover 2948. As described above,reticulated non-visco-elastic foam can reduce the amount of heat (e.g.,from a user's body heat) in adjacent areas of a body support, based atleast in part upon the skeletal cellular structure of the reticulatednon-visco-elastic foam. Therefore, the foam cover 2948 can provideenhanced fire resistance while also serving to ventilate the bodysupport 2902 and/or dissipate heat from the adjacent first and/or secondlayers 2910, 2912 covered by the reticulated non-visco-elastic foamcover 2948. Also, the reticulated non-visco-elastic foam of the cover2948 can be utilized to provide a layer of material that is lessresponsive or substantially non-responsive to a user's body temperature(described in greater detail above in connection with the embodiment ofFIG. 13), while still providing the ventilation and/or heat dissipationproperties also described above.

The reticulated visco-elastic material of the top layer 2910 can providea relatively comfortable substrate for a user's body, can at leastpartially conform to the user's body (to distribute force applied by theuser's body upon the reticulated visco-elastic material of the top layer2910), and can be selected for responsiveness to a range of temperaturesgenerated by body heat of a user. In some embodiments, the reticulatednon-visco-elastic foam cover 2948 (if employed) has a maximum thicknessthrough which these properties are still exhibited. Although thedesirable tactile feel of the reticulated visco-elastic first layer 2910is blocked in some embodiments by the reticulated non-visco-elastic foamcover 2948, the other desirable properties of the reticulatedvisco-elastic material of the first layer 2910 can still be experiencedthrough a sufficiently thin reticulated non-visco-elastic foam cover2948. In some embodiments, the reticulated non-visco-elastic foam cover2948 has a maximum thickness of about 1 cm. In other embodiments, thereticulated non-visco-elastic foam cover 2948 has a maximum thickness ofabout 2 cm. In still other embodiments, the reticulatednon-visco-elastic foam cover 2948 has a maximum thickness of about 5 cm.

FIG. 30 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 29. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 29. Reference should be made to the descriptionabove in connection with FIG. 29 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 30 and describedbelow. Structure and features of the embodiment shown in FIG. 30 thatcorrespond to structure and features of the embodiment of FIG. 29 aredesignated hereinafter in the 3000 series of reference numbers.

Like the body support 2902 illustrated in FIG. 29, the body support 3002illustrated in FIG. 30 has a top layer 3010 comprising reticulatedvisco-elastic foam, a bottom layer 3012 comprising flexible cellularpolyurethane foam having a relatively high resilience, and a cover 3048comprising reticulated non-visco-elastic foam. The reticulatedvisco-elastic foam and the relatively highly resilient flexible cellularfoam of the top and bottom layers 3010, 3012, respectively, aredescribed in greater detail above in connection with the embodimentillustrated in FIGS. 12 and 12A. The reticulated non-visco-elastic foamof the cover 3048 is described in greater detail above in connectionwith the embodiment illustrated in FIG. 13.

The reticulated non-visco-elastic foam cover 3048 of the body support3002 illustrated in FIG. 30 can be selected to provide a heighteneddegree of fire resistance for the body support 3002, and can alsofunction to dissipate heat (e.g., received from a user's body) from theadjacent first and/or second layers 3010, 3012 covered by thereticulated non-visco-elastic foam cover 3048. In this regard, thereticulated non-visco-elastic foam of the cover 3048 can be utilized toprovide a layer of material that is less responsive or is substantiallynon-responsive to a user's body temperature (described in greater detailabove in connection with the embodiment of FIG. 13), while stillproviding the ventilation and/or heat dissipation properties alsodescribed above.

The top surface 3020 of the bottom layer 3012 of the body support 3002has a non-planar shape beneath the substantially planar bottom surface3018 of the top layer 3010. The non-planar shape of the top surface 3020can take any of the forms described above in connection with thenon-planar top surface 420 of the bottom layer 412 in the body support402 illustrated in FIG. 4, and can be defined by a plurality ofprotrusions 3028 and/or a plurality of apertures (not shown) as alsodescribed above. Passages 3030 can be defined between the substantiallyplanar bottom surface 3018 of the top layer 3010 and the non-planar topsurface 3020 of the bottom layer 3012. In other embodiments, suchpassages 3030 can be defined between a non-planar bottom surface 3018 ofthe top layer 3010 and a substantially planar top surface 3020 of thebottom layer 3012, or between a non-planar bottom surface 3018 of thetop layer 3010 and a non-planar top surface 3020 of the bottom layer3012, wherein the non-planar surface(s) can be defined in any of themanners described above in connection with the illustrated embodiment ofFIG. 4.

Passages 3030 running between the top and bottom layers 3010, 3012illustrated in FIG. 30 can supplement the ventilation and/or heatdissipative capabilities of the top layer 3010 of reticulatedvisco-elastic foam, and can prevent or reduce heat in the bottom layer3012 of relatively highly resilient flexible cellular foam. In thisregard, the skeletal structure of the reticulated visco-elastic foamcells in the top layer 3010 can enable heat to be transferred from thetop layer 3010 to and through the passages 3030.

FIG. 31 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 21. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 21. Reference should be made to the descriptionabove in connection with FIG. 21 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 31 and describedbelow. Structure and features of the embodiment shown in FIG. 31 thatcorrespond to structure and features of the embodiment of FIG. 21 aredesignated hereinafter in the 3100 series of reference numbers.

Like the body support 2102 illustrated in FIG. 21, the body support 3102illustrated in FIG. 31 comprises a top layer 3110 of open-cellednon-reticulated visco-elastic foam, a middle layer 3112 comprisingreticulated visco-elastic foam, and a bottom layer 3114 comprisingreticulated non-visco-elastic foam. However, the top layer 3110 furthercomprises portions of reticulated visco-elastic foam that can have thesame or different properties as the reticulated visco-elastic foam inthe middle layer 3112. The non-reticulated visco-elastic foam of the toplayer 3110 is described in greater detail above in connection with theembodiment illustrated in FIG. 16. The reticulated visco-elastic foam ofthe top and middle layers 3110, 3112 is described in greater detailabove in connection with the embodiment illustrated in FIGS. 12 and 12A.The reticulated non-visco-elastic foam of the bottom layer 3114 isdescribed in greater detail above in connection with the embodimentillustrated in FIG. 13.

With continued reference to the illustrated embodiment of FIG. 31, thetop layer 3110 has three portions 3132 comprising reticulatedvisco-elastic foam, each of which are surrounded by other portions 3146of the top layer 3110 comprising the non-reticulated visco-elastic foam.In some embodiments, one or more of the three portions 3132 comprisingreticulated visco-elastic foam can be disposed a distance from adjacentedges of the top layer 3110 by at least about 10 cm and by no greaterthan about 20 cm. In other embodiments, this distance can be at leastabout 10 cm and no greater than about 15 cm. It should be noted thatthis distance can be the same or different at different locations aboutany of the three portions 3132 comprising reticulated visco-elasticfoam, and can be larger or smaller than that illustrated in FIG. 31.

Each of the three portions 3132 comprising reticulated visco-elasticfoam described above can have any shape desired, such as rectangular(see FIG. 31), trapezoidal, triangular, and other polygonal shapes,round, oval, and other rotund shapes, hourglass, star, irregular, andother shapes. Also, the three portions 3132 comprising reticulatedvisco-elastic foam can have the same shape (see FIG. 31) or can havedifferent shapes, and can have the same size (see FIG. 31) or can havedifferent sizes.

The three portions 3132 comprising reticulated visco-elastic foam can belocated in any positions in the top layer 3110. By way of example only,the three portions 3132 illustrated in FIG. 31 are located proximateareas of the body support 3102 where an adult user's head, buttocks, andlower legs would be located when the user is in a supine position on thebody support 3102. In other embodiments, the top layer 3110 can have oneor more portions 3132 of reticulated visco-elastic foam located in anyother position in the top layer 3110, such as two portions 3132 ofreticulated visco-elastic foam located proximate the head and buttocksof a user, a single portion 3132 of reticulated visco-elastic foamlocated proximate the head and/or shoulders of a user, four portions3132 of reticulated visco-elastic foam located proximate the head, back,buttocks, and legs of a user, and the like. In some embodiments, thereticulated visco-elastic foam portion(s) 3132 are located proximateareas that correspond to those areas of a user's body on the bodysupport 3102 that experience the highest pressure when the user is lyingon the body support 3102 in an orientation substantially aligned withthe length L of the body support 3102.

The three portions 3132 comprising reticulated visco-elastic foam in theillustrated embodiment of FIG. 31 are each surrounded by thenon-reticulated visco-elastic foam of the top layer 3110. However, inother embodiments, one or more sides of one or more of the portions 3132are open to a side or end of the top layer 3110, or are otherwise notseparated from a side or end of the top layer 3110 by thenon-reticulated visco-elastic foam.

With continued reference to the illustrated embodiment of FIG. 31, thenon-reticulated visco-elastic foam in the top layer 3110 can provide thedesirable softness, body-conforming, and pressure-distributing featuresdescribed above in connection with the illustrated embodiment of FIG.21. The portions 3132 of the top layer 3110 comprising reticulatedvisco-elastic foam can provide a significant degree of ventilationand/or heat dissipation for areas of the top layer 3110 adjacent theuser's body that could experience the greatest pressure and heat fromthe user's body. These capabilities can supplement the ventilationand/or heat dissipation provided by the reticulated visco-elastic andreticulated non-visco-elastic foams of the middle and bottom layers3112, 3114 described above in connection with the embodiment of FIG. 21.Also, the visco-elastic properties of these portions 3132 can stillprovide a relatively high degree of softness, body-conforming, andpressure-distribution for the user's body.

The top layer 3110 illustrated in FIG. 31 comprises three portions 3132comprising reticulated visco-elastic foam surrounded by other portions3146 comprising non-reticulated visco-elastic foam. In otherembodiments, the materials of these portions 3132, 3146 can be reversed,such that one or more portions comprising non-reticulated visco-elasticfoam are at least partially surrounded by other portions comprisingreticulated visco-elastic foam. In such embodiments, the softness,body-conforming, and pressure-distributing features of the “islands”comprising non-reticulated visco-elastic foam can be located proximatethose areas of a user's body that could experience the greatest pressureand heat from the user's body. The surrounding portions comprisingreticulated visco-elastic foam can also provide a degree of softness,body-conforming, and pressure-distribution while also functioning toprevent or reduce heat in the top layer 3110 by virtue of the skeletalstructure of the reticulated visco-elastic foam.

FIG. 32 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 13. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 13. Reference should be made to the descriptionabove in connection with FIG. 13 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 32 and describedbelow. Structure and features of the embodiment shown in FIG. 32 thatcorrespond to structure and features of the embodiment of FIG. 13 aredesignated hereinafter in the 3200 series of reference numbers.

Like the body support 1302 illustrated in FIG. 13, the body support 3202illustrated in FIG. 32 comprises a top layer 3210 comprising reticulatedvisco-elastic foam and a bottom layer 3212 comprising reticulatednon-visco-elastic foam. However, the top layer 3210 further comprisesportions of open-celled non-reticulated visco-elastic foam. Thereticulated visco-elastic foam of the top layer 3210 is described ingreater detail above in connection with the embodiment illustrated inFIGS. 12 and 12A. The non-reticulated visco-elastic foam of the toplayer 3210 is described in greater detail above in connection with theembodiment illustrated in FIG. 16. The reticulated non-visco-elasticfoam of the bottom layer 3212 is described in greater detail above inconnection with the embodiment illustrated in FIG. 13.

With continued reference to the illustrated embodiment of FIG. 32, thetop layer 3210 has three portions 3232 comprising non-reticulatedvisco-elastic foam, each of which is surrounded by other portions 3246of the top layer 3210 comprising the reticulated visco-elastic foam. Thethree portions 3232 comprising non-reticulated visco-elastic foamillustrated in FIG. 32 are each substantially rectangular, are spacedfrom one another along the length of the top layer 3210, and are spacedfrom the edges of the top layer 3210. However, the three portions 3232can have any other shape and size as described above in connection withthe illustrated embodiment of FIG. 31. Also, the top layer 3210 can haveany number of such portions 3232 located in any of the manners describedabove in connection with the illustrated embodiment of FIG. 31.

With continued reference to the illustrated embodiment of FIG. 32, thenon-reticulated visco-elastic foam in the three portions 3232 of the toplayer 3110 can provide in such areas the desirable softness,body-conforming, and pressure-distributing features described above inconnection with the illustrated embodiment of FIG. 16. The surroundingportions 3246 of the top layer 3210 comprising reticulated visco-elasticfoam can provide significant ventilation and/or heat dissipation to thethree portions 3232 adjacent the user's body, and can draw heat frominternal areas of the top layer 3210 toward the edges of the top layer3210. Such ventilation and/or heat dissipation can supplement theventilation and/or heat dissipation provided by the reticulatednon-visco-elastic foam of the bottom layer 3212 described above inconnection with the embodiment of FIG. 13. Also, the visco-elasticproperties of the surrounding portions 3246 can still provide arelatively high degree of softness, body-conforming, andpressure-distribution for the user's body.

FIG. 33 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 31. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 31. Reference should be made to the descriptionabove in connection with FIG. 31 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 33 and describedbelow. Structure and features of the embodiment shown in FIG. 33 thatcorrespond to structure and features of the embodiment of FIG. 31 aredesignated hereinafter in the 3300 series of reference numbers.

Like the body support 3102 illustrated in FIG. 31, the body support 3302illustrated in FIG. 33 comprises a top layer 3310 having a combinationof open-celled non-reticulated visco-elastic foam (portion 3346) andreticulated visco-elastic foam (portion 3332). However, the body support3302 illustrated in FIG. 33 has a bottom layer 3312 comprising flexiblecellular polyurethane foam having a relatively high resilience, ratherthan the layers of reticulated visco-elastic and reticulatednon-visco-elastic foam in the embodiment of FIG. 31. The non-reticulatedvisco-elastic foam of the top layer 3310 is described in greater detailabove in connection with the embodiment illustrated in FIG. 16. Thereticulated visco-elastic foam of the top layer 3310 is described ingreater detail above in connection with the embodiment illustrated inFIGS. 12 and 12A. The relatively highly resilient flexible cellular foamof the bottom layer 3312 is also described in greater detail above inconnection with the embodiment illustrated in FIGS. 12 and 12A.

The top layer 3310 illustrated in FIG. 33 includes a border 3346comprising the non-reticulated visco-elastic foam, which extends fullyaround a portion 3332 of the top layer 3310 comprising the reticulatedvisco-elastic foam. The border 3346 can extend fully around the portion3332 comprising the reticulated visco-elastic foam as shown in FIG. 33,or can extend partially about the portion 3332 comprising thereticulated visco-elastic foam (e.g., having portions flanking the firstportion 3332 as described above with reference to the bottom layer 712of the embodiment of FIG. 7, or having one or more portions shaped andlocated in any of the manners described above in connection with thebottom layer 712 in the illustrated embodiment of FIG. 7). In short, anynumber of portions 3332 comprising the reticulated visco-elastic foamand any number of borders 3346 comprising the non-reticulatedvisco-elastic foam can have any of the shapes, positions, andarrangements described above in connection with the bottom layer 712 inthe illustrated embodiment of FIG. 7.

With continued reference to the illustrated embodiment of FIG. 33, thenon-reticulated visco-elastic foam in the top layer 3310 can provide thedesirable softness, body-conforming, and pressure-distributing featuresdescribed above (in connection with the illustrated embodiment of FIG.19) along the periphery of the top layer 3310, such as in locationswhere a user enters or exits the body support (e.g., in mattressapplications). The portion 3332 of the top layer 3310 comprisingreticulated visco-elastic foam can provide ventilation and/or heatdissipation for an interior area of the top layer 3310 upon which a userwill most likely rest for a prolonged period of time, and to which auser's body heat would most likely be transferred. The ventilation andheat dissipative properties of the reticulated visco-elastic foam in thetop layer 3310 can also reduce heat in the underlying layer ofrelatively highly resilient flexible cellular foam (which can be used toprovide additional support, and a relatively stiff but flexible andresilient substrate beneath the top layer 3310).

As described above, the top layer 3310 illustrated in FIG. 33 includesan interior portion 3332 comprising reticulated visco-elastic foamsurrounded by other portions 3346 comprising non-reticulatedvisco-elastic foam. In other embodiments, the materials of theseportions 3332, 3346 can be reversed, such that one or more portionscomprising non-reticulated visco-elastic foam are at least partiallysurrounded by one or more other portions comprising reticulatedvisco-elastic foam. Such alternative embodiments and their features andcharacteristics are described in greater detail above in connection withthe illustrated embodiment of FIG. 31.

FIG. 34 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 31. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 31. Reference should be made to the descriptionabove in connection with FIG. 31 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 34 and describedbelow. Structure and features of the embodiment shown in FIG. 34 thatcorrespond to structure and features of the embodiment of FIG. 31 aredesignated hereinafter in the 3400 series of reference numbers.

Like the body support 3102 illustrated in FIG. 31, the body support 3402illustrated in FIG. 34 comprises a top layer 3410 having a combinationof open-celled non-reticulated visco-elastic foam (portion 3432) andreticulated visco-elastic foam (portions 3434, 3436), and a middle layer3412 comprising reticulated visco-elastic foam. However, the bodysupport 3402 illustrated in FIG. 34 has a bottom layer 3414 comprisingflexible cellular polyurethane foam having a relatively high resilience,rather than a layer of reticulated non-visco-elastic foam (as in theembodiment of FIG. 31). The non-reticulated visco-elastic foam of thetop layer 3410 is described in greater detail above in connection withthe embodiment illustrated in FIG. 16. The reticulated visco-elasticfoam of the top and middle layers 3410, 3412 is described in greaterdetail above in connection with the embodiment illustrated in FIGS. 12and 12A. The relatively highly resilient flexible cellular foam of thebottom layer 3414 is also described in greater detail above inconnection with the embodiment illustrated in FIGS. 12 and 12A.

The portions 3434, 3436 of reticulated visco-elastic foam illustrated inFIG. 34 define side borders of the top layer 3410, and can have any ofthe shapes, sizes, and locations described above with reference to thesecond and third portions 734, 736 of the bottom layer 712 illustratedin FIG. 7. The non-reticulated visco-elastic foam portion 3432 of thetop layer 3410 can provide the desirable softness, body-conforming, andpressure-distributing features described above in connection with theillustrated embodiment of FIG. 16. The portions 3434, 3436 ofreticulated visco-elastic foam of the top layer 3410 can provide adegree of ventilation and/or heat dissipation for the interior portion3432 adjacent the user's body, and can draw heat from internal areas ofthe top layer 3410 toward the sides and ends of the top layer 3410. Suchventilation and/or heat dissipation can supplement the ventilationand/or heat dissipation provided by the reticulated visco-elastic foamof the middle layer 3412. Also, the visco-elastic properties of theportions 3434, 3436 of reticulated visco-elastic foam can still providea relatively high degree of softness, body-conforming, andpressure-distribution for the user's body at the sides of the top layer3410 (e.g., in locations where a user may enter or exit the body support3420, such as in mattress applications).

The ventilation and heat dissipative properties of the reticulatedvisco-elastic foam in the portions 3434, 3436 of the top layer 3310 andin the middle layer 3412 can also reduce heat in the bottom layer 3414of relatively highly resilient flexible cellular foam (which can be usedto provide additional support, and a relatively stiff but flexible andresilient substrate upon which the top and middle layers 3410, 3412lie).

As described above, the top layer 3410 illustrated in FIG. 34 includesan interior portion 3432 comprising non-reticulated visco-elastic foamflanked by portions 3434, 3436 comprising reticulated visco-elasticfoam. In other embodiments, the materials of these portions 3432 and3434, 3436 can be reversed. Such alternative embodiments can thereforeinclude a portion of reticulated visco-elastic foam flanked by andproviding ventilation and/or heat dissipation to adjacent portions ofnon-reticulated visco-elastic foam.

One or more of the layers of material in each of the body supportembodiments described above can comprise material in slab or block form.For example, each of the illustrated layers of material in FIGS. 1-34 isillustrated as a sheet of foam. In this regard, any or all of suchlayers in any of the embodiments can each be defined by a single,continuous, and unbroken sheet of material. Alternatively, one or moreof such layers can be defined by two or more pieces of material coupledin any suitable manner, such as by adhesive or cohesive bondingmaterial, double-sided tape, stitching, hot-melting, conventionalfasteners, by being molded together in one or more manufacturingprocesses, or in any other suitable manner. Such pieces of material canhave any shape and size desired, such as blocks, strips, pads, or balls,pieces having polygonal, curvilinear, irregular, or other shapes, andthe like. Also, such pieces of material can be identical to or differentfrom one another in shape and/or size.

In some embodiments, one or more of the layers of material in any of thebody support embodiments described above and illustrated in FIGS. 1-34comprise pieces of material that are not coupled together. For example,any one or more of such layers can include loose pieces of materialhaving any shape and size as described above, wherein the pieces arepartially or entirely enclosed and contained within one or more layersof material. In such embodiments, the enclosing layer(s) of material cancomprise synthetic and/or natural fabric, cloth, or other sheetmaterial. In some embodiments, the enclosing layer(s) can have one ormore seams attached by adhesive or cohesive bonding material,double-sided tape, stitching, hot-melting, conventional fasteners (e.g.,zippers, buttons, clasps, laces, hook and loop fastener material, hookand eye sets, tied ribbons, strings, cords, or other similar elements,and the like), by being molded together in one or more manufacturingprocesses, or in any other suitable manner. One or more of suchenclosing layers can also partially or entirely enclose and containlayers comprising pieces of material coupled together as describedabove.

An example of a body support 3502 comprising pieces of material withinone or more enclosing layers is illustrated in FIG. 35. The body support3502 illustrated in FIG. 35 is in the shape of a pillow, although itshould be noted that the body support 3502 can take any other shape andhave any other size for any other body support application (e.g.,mattresses, mattress toppers, overlays, futons, seat cushions, seatbacks, neck pillows, leg spacer pillows, eye masks, and any other shapeand size suitable for supporting or cushioning any part or all of ahuman or animal body).

The body support 3502 illustrated in FIG. 35 comprises filler material3558 surrounded by an enclosing layer of material 3560. The fillermaterial 3558 illustrated in FIG. 35 includes separate pieces ofmaterial that are not coupled together, although in other embodimentssome or all of the pieces can be coupled to adjacent pieces (such asseparate pieces coupled together in one or more manufacturing processesas described above). In some embodiments, the filler material 3558comprises a plurality of pieces of non-reticulated visco-elastic foamhaving any of the material properties described above in connection withthe material of top layer 110 in the illustrated body support 102 ofFIG. 1. The body supports 3502 of these embodiments can thereforeprovide significant softness and can conform to a user's body, and insome cases can provide a greater degree of body support deformabilitydue to the multiple-piece construction of the body support 3502. Suchdeformability can be desirable in many applications, such as in pillowsand cushions adapted to support portions of a user's body, by way ofexample only. Also, the temperature sensitivity of body supports 3502having non-reticulated visco-elastic filler material 3558 can enable thebody support to better adapt to a user's body (as described in greaterdetail above in connection with the non-reticulated visco-elasticmaterial utilized in the embodiment of FIGS. 1-1B), thereby distributingpressure and increasing user comfort.

With continued reference to the illustrated embodiment of FIG. 35, thepieces of non-reticulated visco-elastic foam in the filler material 3558can be produced by shredding or cutting non-reticulated visco-elasticfoam, whether in virgin, recycled, or scrap form. Alternatively, thepieces of non-reticulated visco-elastic foam can be produced by moldingthe individual pieces or in any other manner.

As described above, the pieces of non-reticulated visco-elastic foam inthe filler material 3558 can have any size and shape desired. However,in some embodiments, these pieces have an average largest dimension ofno greater than about 4 cm and/or no less than about 0.3 cm. In otherembodiments, the pieces have an average largest dimension of no greaterthan about 2 cm and/or no less than about 0.6 cm. In still otherembodiments, the pieces have an average largest dimension of about 1.3cm.

The filler material 3558 of the body support 3502 illustrated in FIG. 35can be varied to change the characteristics and/or cost of the bodysupport 3502. For example, substantially all of the filler material 3558can comprise unconnected pieces of non-reticulated visco-elastic foam asdescribed above, or can comprise a combination of such pieces and piecesof another material (e.g., cotton, synthetic or organic fiber material,feathers, another type of foam material, polystyrene balls, and thelike). In this regard, the filler material 3558 of the body support 3502can comprise no less than about 20% non-reticulated visco-elastic foampieces in some embodiments. In other embodiments, the filler material3558 of the body support 3502 comprises no less than about 30%non-reticulated visco-elastic foam pieces. In still other embodiments,the filler material 3558 of the body support 3502 comprises no less thanabout 50% non-reticulated visco-elastic foam pieces. The density andother characteristics of the other material (if any) in the fillermaterial 3558 can help to define the density and other characteristicsof the filler material 3558.

As described above, the filler material 3558 in the illustratedembodiment of FIG. 35 is surrounded by an enclosing layer of material3560, which can have one or more seams coupled together as described ingreater detail above. In some embodiments, the enclosing layer 3560comprises reticulated non-visco-elastic foam having any of the materialproperties described above in connection with the material of the bottomlayer 112 in the illustrated body support 102 of FIG. 1. The enclosinglayer 3560 can have any thickness desired. In some embodiments, theenclosing layer 3560 of reticulated non-visco-elastic foam has athickness of no less than about 5 mm and/or no greater than about 20 mm.Relatively lightweight body supports in some embodiments can have athickness of no greater than about 7 mm, while relatively heavy weightbody supports in some embodiments can have a thickness of no less thanabout 13 mm.

With continued reference to the body support 3502 illustrated in FIG.35, the enclosing layer 3560 of non-visco-elastic foam can provide asignificant degree of ventilation and/or heat dissipation for the bodysupport 3502, and can prevent or reduce heat in the filler material 3558of the body support 3502.

In some embodiments, the enclosing layer 3560 of the body support 3502is partially or entirely covered with one or more reinforcing fabriclayers (not shown), which in some embodiments can act as an anchor forstitches or other fastening elements securing portions of the enclosinglayer 3560 together (e.g., at seams of the enclosing layer 3560),thereby reducing the opportunity for stitches or other fasteningelements to rip or tear through the enclosing layer 3560. If employed,the reinforcing fabric layer(s) can comprise cotton, polyester, acotton/polyester blend, wool, or any other fabric material.

A cover 3562 can at least partially surround the enclosing layer 3560and filler material 3558 of the body support 3502, can be removable fromthe rest of the body support 3502, and in some embodiments can conformto the shape of the body support 3502. The cover 3562 can comprise anyfabric material, such as a cotton, polyester, cotton/polyester blend,wool, and the like. Also, the cover 3562 can have one or more closuredevices 3564, such as one or more zippers (see FIG. 35), snaps, buttons,clasps, laces, pieces of hook and loop fastener material, hook and eyesets, overlapping flaps, tied ribbons, strings, cords, or other similarelements, and the like, in order to retain the enclosing layer 3560 andfiller material 3558 within the cover 3562.

As described above, the enclosing layer 3560 of the body support 3502illustrated in FIG. 35 comprises reticulated non-visco-elastic foam,which can provide any of the features also described above. In otherembodiments, all or part of the enclosing layer 3560 can comprisereticulated visco-elastic foam having any of the enclosing layerthicknesses described above, and having any of the material propertiesdescribed above in connection with the material of the top layer 1210 inthe illustrated body support 1202 of FIG. 12. An enclosing layer 3560comprising reticulated visco-elastic material can have an improvedability to conform to a user's body while still providing a significantdegree of ventilation and/or heat dissipation for the body support 3502,and can prevent or reduce heat in the filler material 3558 of the bodysupport 3502. In this regard, such an enclosing layer 3560 can betemperature-sensitive to a user's body heat, thereby better enabling theenclosing layer 3560 to perform the body-conforming function describedabove.

As described above, the illustrated body support 3502 can comprisenon-reticulated visco-elastic filler material 3558 at least partiallysurrounded by one or more enclosing layers 3560 of reticulatedvisco-elastic or reticulated non-visco-elastic foam as described above.In alternative embodiments, the filler material 3558 can instead or alsoinclude a plurality of unconnected reticulated non-visco-elastic foampieces having any of the size and shape properties described above withreference to the non-reticulated visco-elastic foam filler material 3558illustrated in FIG. 35. Such reticulated non-visco-elastic foam piecescan be produced in any of the manners described above in connection withthe non-reticulated visco-elastic foam filler material 3558 illustratedin FIG. 35, can define any part of the filler material 3558 of the bodysupport 3502 in combination with any of the other filler materials asalso described above, or can define all of the filler material 3558 ofthe body support 3502. Also, such reticulated non-visco-elastic foampieces can have any of the material properties described above inconnection with the material of the bottom layer 112 in the illustratedbody support 102 of FIG. 1.

The construction of a body support 3502 with filler material 3558comprising pieces of reticulated non-visco-elastic foam within anenclosing layer 3560 of reticulated visco-elastic or reticulatednon-visco-elastic foam as described above can provide a relatively highdegree of ventilation in and through the filler material 3558 as well asthe enclosing layer 3560. This construction can also enable heat to berapidly dissipated from the body support 3502, thereby preventing orreducing heat in areas of the body support 3502. In those applicationsin which the temperature-sensitive, body-conforming, and pressuredistribution properties of visco-elastic foam are desired on orimmediately adjacent the exterior of the body support 3502, theenclosing layer 3560 can comprise reticulated visco-elastic foam.Alternatively, if such features are instead desired only in the interiorof the body support 3502 (e.g., to provide an exterior that is lesssubject to change, such as resulting from a user's body heat), theenclosing layer 3560 can comprise reticulated non-visco-elastic foam.

In other embodiments of the present invention, the body supportillustrated in FIG. 35 can comprise one or more enclosing layers 3560 ofreticulated visco-elastic or reticulated non-visco-elastic foam (asdescribed above) at least partially surrounding filler materialcomprising a plurality of unconnected reticulated visco-elastic foampieces. The reticulated visco-elastic foam pieces can have any of thesize and shape properties described above with reference to thenon-reticulated visco-elastic foam filler material 3558 illustrated inFIG. 35. Such reticulated visco-elastic foam pieces can be produced inany of the manners described above in connection with thenon-reticulated visco-elastic foam filler material 3558 illustrated inFIG. 35, can define any part of the filler material 3558 of the bodysupport 3502 in combination with any of the other filler materials asalso described above, or can define all of the filler material 3558 ofthe body support 3502. Also, such reticulated visco-elastic foam piecescan have any of the material properties described above in connectionwith the material of the top layer 1210 in the illustrated body support1202 of FIG. 12.

The construction of a body support 3502 with filler material 3558comprising pieces of reticulated visco-elastic foam within an enclosinglayer 3560 of reticulated visco-elastic or reticulated non-visco-elasticfoam as described above can provide a relatively high degree ofventilation in and through the filler material 3558 as well as theenclosing layer 3560, while still providing the desirabletemperature-sensitivity, body-conforming, and pressure distributionproperties of the visco-elastic filler material (and visco-elasticenclosing layer, if used) as described in greater detail above inconnection with the body support 1202 of FIGS. 12 and 12A. Thisconstruction can also enable heat to be rapidly dissipated from the bodysupport 3502, thereby preventing or reducing heat in areas of the bodysupport 3502. As described above, in those applications in which thetemperature-sensitive, body-conforming, and pressure distributionproperties of visco-elastic foam are desired on or immediately adjacentthe exterior of the body support 3502, the enclosing layer 3560 cancomprise reticulated visco-elastic foam. Alternatively, if such featuresare instead desired only in the interior of the body support 3502 (e.g.,to provide an exterior that is less subject to change, such as resultingfrom a user's body heat), the enclosing layer 3560 can comprisereticulated non-visco-elastic foam.

In still other embodiments of the present invention, the reticulatedvisco-elastic or reticulated non-visco-elastic enclosing layer 3560 ofthe body support 3502 illustrated in FIG. 35 and described above can bereplaced by a non-reticulated visco-elastic enclosing layer 3560 atleast partially enclosing pieces of unconnected reticulatedvisco-elastic or reticulated non-visco-elastic foam (also describedabove). The non-reticulated visco-elastic enclosing layer 3560 can haveany of the enclosing layer thicknesses described above, and can have anyof the material properties described above in connection with thematerial of the top layer 110 in the illustrated body support 102 ofFIG. 1. A non-reticulated visco-elastic enclosing layer 3560 can providea high degree of softness and user comfort, while also providing thedesirable temperature-sensitivity, body-conforming, and pressuredistribution properties described above in connection with the materialof the top layer 110 in the illustrated body support 102 of FIG. 1. Thepieces of reticulated visco-elastic or reticulated non-visco-elasticfoam within such an enclosing layer 3560 can help to dissipate heatwithin the body support 3502, thereby reducing heat in one or more areasof the body support 3502.

FIG. 36 illustrates another embodiment of a body support according tothe present invention. This embodiment employs much of the samestructure and has many of the same properties as the embodiments of thebody support described above in connection with FIG. 35. Accordingly,the following description focuses primarily upon the structure andfeatures that are different than the embodiments described above inconnection with FIG. 35. Reference should be made to the descriptionabove in connection with FIG. 35 for additional information regardingthe structure and features, and possible alternatives to the structureand features of the body support illustrated in FIG. 36 and describedbelow. Structure and features of the embodiment shown in FIG. 36 thatcorrespond to structure and features of the embodiment of FIG. 35 aredesignated hereinafter in the 3600 series of reference numbers.

Like the body support embodiments described above in connection with thebody support 3502 illustrated in FIG. 35, the body support 3602illustrated in FIG. 36 comprises filler material 3658 surrounded by anenclosing layer of material 3660. However, the body support 3602 canalso include a pocket 3666 of additional filler material 3668 comprisingpieces of reticulated visco-elastic material. In the illustratedembodiment of FIG. 36, these pieces of material are unconnected, can beproduced in any of the manners described above in connection with theembodiment of FIG. 35, and can have any of the material properties,shapes, and sizes also described above in connection with the embodimentof FIG. 35. In other embodiments, some or all of the pieces ofreticulated visco-elastic material are connected to one another.

The pocket 3666 of additional filler material 3668 can be at leastpartially defined by fabric or other sheet material within which thereticulated visco-elastic pieces are located. In this regard, the pocket3666 can have any of the forms described above with reference to theenclosing layer of material 3560 of FIG. 35, and can be connected to theenclosing layer of material 3660 in any of the manners described abovewith reference to the construction of seams in the embodiment of FIG.35. In other embodiments, the material at least partially defining thepocket 3666 is not connected to any other potion of the body support3602, although is still contained within the enclosing layer of material3660.

Using the body support construction illustrated in FIG. 36, the piecesof reticulated visco-elastic filler material 3668 can be kept frommixing with the surrounding filler material 3658 contained within theenclosing layer 3660 of the body support 3602. Such a construction canbe desirable in those embodiments in which the surrounding fillermaterial 3658 is different than the filler material 3668 within thepocket 3666, such as when the surrounding filler material 3658 comprisesnon-reticulated visco-elastic foam pieces or reticulated non-viscoelastic foam pieces. In some of these examples, the surrounding fillermaterial 3658 can still provide the desirable softness, body-conforming,and pressure distribution features within the body support 3602, whilethe reticulated visco-elastic foam pieces within the pocket 3666 providea region within the body support 3602 capable of providing ventilationbetween different internal areas of the body support 3602 and/ordissipating heat within the body support 3602. These functions can beperformed regardless of whether the enclosing layer 3660 comprisesnon-reticulated visco-elastic material, reticulated visco-elasticmaterial, or reticulated non-visco-elastic material (all of which can beutilized in the enclosing layer 3660, as described above).

The reticulated visco-elastic filler material 3668 within the pocket3666 of the body support 3602 illustrated in FIG. 36 can function toprovide ventilation and/or to dissipate heat within the body support3602 (as just described) while still being responsive to a user's bodyheat, and while still providing the body-conforming and pressuredistribution functions by virtue of the visco-elastic nature of thefiller material 3668. In other embodiments, the filler material 3668within the pocket 3666 can instead comprise connected or unconnectedreticulated non-visco-elastic foam pieces. Such pieces can be producedin any of the manners described above in connection with the embodimentof FIG. 35, and can have any of the material properties, shapes, andsizes also described above in connection with the embodiment of FIG. 35.By employing non-reticulated visco-elastic foam for the pieces of fillermaterial 3668 within the pocket 3666, the stiffness of the body support3602 can be less sensitive to a user's body heat while still performingthe ventilating and/or heat dissipating function described above.

Another embodiment of a body support according to the present inventionis illustrated in FIGS. 37 and 38. The body support 3702 illustrated inFIGS. 37 and 38 is a pillow having a contoured shape. However, the bodysupport 3702 can have any other pillow shape desired. The body support3702 can comprise a single piece of reticulated visco-elastic foammanufactured by molding or in any other suitable manner. In otherembodiments, the body support 3702 can be defined by two or more piecesof reticulated visco-elastic foam connected in any of the mannersdescribed above with reference to multi-piece foam layer construction.The reticulated visco-elastic foam of the body support 3702 can have anyof the material properties described above in connection with thematerial of the top layer 1210 in the illustrated body support 1202 ofFIG. 12.

The body support 3702 illustrated in FIGS. 37 and 38 can provide supportfor a user while still conforming to a user's body (e.g., head and neck)based upon the visco-elastic nature of the body support material.Accordingly, the reticulated visco-elastic material of the body support3702 can distribute pressure from the user's body across the surface ofthe body support 3702, thereby potentially reducing stress upon theuser's neck and/or reducing pressure upon the user's face or other areaof the user's head in contact with the body support 3702. In thoseembodiments in which the reticulated visco-elastic foam istemperature-sensitive as described above, the shape of the body support3702 can also be adapted to the user based upon the user's body heat.Also, the reticulated visco-elastic material of the body support 3702can provide an increased amount of ventilation and/or heat dissipationbased upon the skeletal cellular structure of the foam, thereby reducingheat in the body support 3702.

FIGS. 39 and 40 illustrate another embodiment of a body supportaccording to the present invention. This embodiment employs much of thesame structure and has many of the same properties as the embodiments ofthe body support described above in connection with FIG. 16.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIG. 16. Reference should be made to thedescription above in connection with FIG. 16 for additional informationregarding the structure and features, and possible alternatives to thestructure and features of the body support illustrated in FIGS. 39 and40 and described below. Structure and features of the embodiment shownin FIGS. 39 and 40 that correspond to structure and features of theembodiment of FIG. 16 are designated hereinafter in the 3900 series ofreference numbers.

As described above, the various body supports of the present inventioncan have any shape and size desired for any body support application,including without limitation body supports used for mattress, mattresstopper, overlay, futon, head pillow, seat cushion, seat back, neckpillow, leg spacer pillow, eye mask, and other applications upon whichany part or all of a human or animal body is supported or cushioned. Thebody support 3902 illustrated in FIGS. 39 and 40 is an example of how abody support illustrated herein in the form of a mattress, mattresstopper, overlay, or futon (e.g., see FIG. 16) can take the form of apillow or other body support (e.g., see FIGS. 39 and 40). Like the bodysupport 1602 illustrated in FIG. 16, the body support 3902 illustratedin FIGS. 39 and 40 has a first layer 3910 of reticulated visco-elasticfoam and a second layer 3912 of non-reticulated visco-elastic foam.However, the first layer 3910 of reticulated visco-elastic foamillustrated in FIGS. 39 and 40 encloses the second layer 3912 ofnon-reticulated visco-elastic foam. In other embodiments, the firstlayer 3910 can cover any portion of the second layer 3912, such as onlythe top 3916 and sides 3670 of the second layer 3912, only the top 3916of the second layer 3912, and the like.

The visco-elastic material of the second layer 3912 can provide the samedesirable softness and body-conforming features described above inconnection with the illustrated embodiment of FIGS. 1-1B. The firstlayer 3910 of reticulated visco-elastic foam can provide ventilation forthe second layer 3912 of non-reticulated visco-elastic foam, and/or candissipate heat from the second layer 3912 (due at least in part to theskeletal cellular structure of the foam of the first layer 3912), whilestill providing a relatively soft and comfortable surface of the bodysupport 3902 and a degree of body-conforming and pressure distributionfor the user's body by virtue of the visco-elastic nature of the firstlayer 3910. Also, the reticulated cellular structure of the first layer3912 can provide improved ventilation at the surface of the body support3902—a feature that can be desirable for applications in which a user'sface, head, or other body portion is in close proximity to or in contactwith the first layer 3910.

In other embodiments, the first layer 3910 of the body support 3902illustrated in FIGS. 39 and 40 comprises reticulated non-visco-elasticfoam (rather than reticulated visco-elastic foam). In such embodiments,the reticulated non-visco-elastic foam of the first layer 3910 canprovide a degree of support while still retaining the heat-dissipativeand/or ventilating properties described above due to the reticulatedcellular structure of the first layer 3910. A body support 3902 havingsuch a construction can also have significant softness and bodyconforming properties, based at least in part upon the non-reticulatedvisco-elastic foam in the second layer 3912.

In still other embodiments, the materials of the first and second layers3910, 3912 described above can be reversed, in which case the firstlayer 3910 can comprise non-reticulated visco-elastic foam, and thesecond layer 3912 can comprise reticulated visco-elastic foam orreticulated non-visco-elastic foam. In such alternative embodiments,heat can be dissipated from the first layer 3910 by the reticulatedvisco-elastic or reticulated non-visco-elastic foam of the second layer3912 (due at least in part to the skeletal cellular structure of thefoam of the second layer 3912). In this structure, the softness,body-conforming, and pressure-distributing properties of thenon-reticulated visco-elastic foam are retained in the first layer 3910(proximate the body of a user) while the ventilating and/orheat-dissipative properties of the second layer 3912 can prevent orreduce heat in the first layer 3910. In those applications in whichgreater support independent of the user's body heat is desired, thesecond layer 3912 can comprise reticulated non-visco-elastic foam. Inthose applications in which temperature-sensitivity, greater softness,and increased body-conforming and pressure distribution is desired, thesecond layer 3912 can comprise reticulated visco-elastic foam.

FIGS. 41 and 42 illustrate another embodiment of a body supportaccording to the present invention. This embodiment employs much of thesame structure and has many of the same properties as the embodiments ofthe body support described above in connection with FIGS. 39 and 40.Accordingly, the following description focuses primarily upon thestructure and features that are different than the embodiments describedabove in connection with FIGS. 39 and 40. Reference should be made tothe description above in connection with FIGS. 39 and 40 for additionalinformation regarding the structure and features, and possiblealternatives to the structure and features of the body supportillustrated in FIGS. 41 and 42 and described below. Structure andfeatures of the embodiment shown in FIGS. 41 and 42 that correspond tostructure and features of the embodiment of FIGS. 39 and 40 aredesignated hereinafter in the 4100 series of reference numbers.

Like the body support 3902 illustrated in FIGS. 39 and 40, the bodysupport 4102 illustrated in FIGS. 41 and 42 has a first layer 4110 ofreticulated visco-elastic foam and a second layer 4112 ofnon-reticulated visco-elastic foam. The second layer 4112 can bepartially or fully enclosed within the material of the first layer 4110,and can have any shape and size desired. By way of example only, thesecond layer 4112 illustrated in FIG. 42 is substantially block-shaped,and is relatively thick and elongated.

The body support 4102 can be manufactured in any manner desired. In someembodiments, the body support 4102 is manufactured by molding the firstlayer 4110 of reticulated visco-elastic foam over the second layer 4112of non-reticulated visco-elastic foam. In such embodiments, the secondlayer 4112 can be an insert within the mold about which the reticulatedvisco-elastic foam of the first layer 4110 is formed. It will beappreciated that other manners of manufacturing the body support 4102with an insert comprising non-reticulated visco-elastic foam arepossible, and fall within the spirit and scope of the present invention.

In other embodiments, the first layer 4110 in the body support 4102illustrated in FIGS. 41 and 42 comprises reticulated non-visco-elasticfoam (rather than reticulated visco-elastic foam). In such embodiments,the body support 4102 can be manufactured in any of the manners justdescribed. Further description of the properties of such a body supportconstruction are provided above in connection with the embodiment ofFIGS. 39 and 40.

In still other embodiments, the materials of the first and second layers4110, 4112 described above can be reversed, in which case the firstlayer 4110 can comprise non-reticulated visco-elastic or reticulatednon-visco-elastic foam, and the second layer 4112 can comprisereticulated visco-elastic foam. Further description of the properties ofsuch a body support construction are provided above in connection withthe embodiment of FIGS. 39 and 40.

In those embodiments of the present invention disclosed herein havingone or more layers of material, any layer can itself be defined by oneor more “sub-layers” of the same type of material (e.g., open-cellednon-reticulated visco-elastic foam, reticulated visco-elastic foam,reticulated non-visco-elastic foam, flexible cellular polyurethane foamhaving a relatively high resilience). In this regard, any of the layerscan be defined by any number of such sub-layers. Also, the sub-layers ineach layer can have the same or different thickness, and can have any ofthe layer shapes, surface profiles, or other features described andillustrated herein.

By way of example only, the body support 4302 illustrated in FIG. 43 hasthe same layers arranged in the same order as the body support 2202illustrated in FIG. 22. However, the top layer 4310 of open-cellednon-reticulated visco-elastic foam illustrated in FIG. 43 comprises twosub-layers 4310 a, 4310 b of open-celled non-reticulated visco-elasticfoam. Similarly, any of the other layers 4312, 4314 can instead or alsocomprise two or more sub-layers of material (i.e., two or moresub-layers of reticulated visco-elastic foam in the middle layer 4312,two or more sub-layers of relatively highly resilient flexible cellularfoam in the bottom layer 4314, and the like).

In those embodiments having one or more layers defined by two or moresub-layers of the same type of material (as just described), thesub-layers can have the same or substantially the same materialproperties. However, this need not necessarily be the case. In thisregard, the sub-layers can have different densities, hardnesses,temperature responsiveness or insensitivity, and other materialproperties while still falling within the ranges of such propertiesdisclosed herein. With reference again to the body support 4302illustrated in FIG. 43 by way of example only, the top sub-layer 4310 aof non-reticulated visco-elastic foam has a greater density and lowerhardness than that of the bottom sub-layer 4310 b of non-reticulatedvisco-elastic foam. For example, in some embodiments, the top sub-layer4310 a of non-reticulated visco-elastic foam can have a density of about110 kg/m³, and a hardness of no less than about 40 N and/or no greaterthan about 50 N, while the bottom sub-layer 4310 b of non-reticulatedvisco-elastic foam can have a density of no less than about 85 kg/m³,and a hardness of no less than about 50 N and/or no greater than about65 N. In this manner, a relatively soft (and, in some cases, relativelyexpensive) visco-elastic body support material can be utilized in alocation where user sensitivity can be most demanding, while the cost ofthe top layer 4310 can be reduced by utilizing less expensivevisco-elastic foam in the bottom sub-layer 4310 b and/or while thesupport of the top layer 4310 can be increased by utilizing a firmerbottom sub-layer 4310 b.

It will be appreciated that a first sub-layer in any layer of any bodysupport disclosed herein can have a higher or lower density, hardness,temperature responsiveness, temperature insensitivity, or other materialproperty than an underlying second sub-layer. In this regard, suchdifferences in material properties can exist in sub-layers ofnon-reticulated visco-elastic foam and reticulated non-visco-elasticfoam; and reticulated visco-elastic foam and relatively highly resilientflexible cellular foam, the properties of which are described above withreference to the embodiments of FIGS. 1-1B and 2-2A, respectively. Inmany cases, the material properties of the sub-layers can impact thecost of the layer and/or the manner in which the layer (and bodysupport) responds to pressure, deformation, and other environmentalconditions.

Any of the body supports disclosed herein can have one or more covers atleast partially enclosing one or more of the body support layers. Eachcover can fully or partially enclose a single layer of the body support,or two or more layers of the body support, as desired. Also, each covercan cover any or all surfaces of one or more layers, such as the top ofa layer, the top and sides of a layer, one or more sides of a layer oradjacent layers, and the like. With reference again to the illustratedembodiment of FIG. 43 by way of example only, the illustrated bodysupport 4302 comprises two covers: a first cover 4372 enclosing the topand middle layers 4310, 4312 of the body support 4302 and a second cover4374 enclosing the bottom layer 4314 of the body support 4302. Also withreference to the embodiment of FIG. 43, the second cover 4374 can coverportions of the body support foundation 4376 (described in greaterdetail below).

The covers 4372, 4374 can comprise any sheet material desired, includingwithout limitation any synthetic and/or natural fabric or clothmaterial, such as cotton, polyester, a cotton/polyester blend, wool,visco-elastic or non-visco-elastic foam sheeting, and the like, and canbe made of the same or different materials. In some embodiments, eachcover 4372, 4374 can have one or more seams. Depending at least in partupon the type of cover material utilized, the seams can be attached byadhesive or cohesive bonding material, double-sided tape, stitching,hot-melting, conventional fasteners (e.g., zippers, buttons, clasps,laces, hook and loop fastener material, hook and eye sets, tied ribbons,strings, cords, or other similar elements, and the like), by beingmolded together in one or more manufacturing processes, or in any othersuitable manner.

The covers 4372, 4374 can be secured permanently to and/or about thelayers 4312, 4314, 4316 which the covers 4372, 4374 at least partiallyenclose. In some embodiments, the covers 4372, 4374 are removable fromsuch layers 4312, 4314, 4316, such as by being shaped to slip onto andoff of the layers, by one or more releasable fasteners (e.g., zippers,buttons, clasps, laces, hook and loop fastener material pieces, hook andeye sets, tied ribbons, strings, cords, or other similar elements), andthe like. Any such fasteners can be positioned to releasably secure atleast one portion of a cover 4372, 4374 to another portion of the sameor different cover 4372, 4374 and/or to an adjacent layer 4312, 4314,4316. For example, the top cover 4372 illustrated in FIG. 43 can have azippered slot (not shown) through which the top and middle layers 4310,4312 of the body support 4302 can be moved to install and remove the topcover 4372.

With continued reference to the illustrated embodiment of FIG. 43, thebody support 4302 in some embodiments of the present invention can besupported upon a foundation 4376 in an elevated position with respect toa floor surface. The foundation 4376 can take any form suitable forsupporting the weight of the body support 4302 under normal or heavyloading. For example, the foundation 4376 can be constructed of beams,poles, tubes, planks, plates, blocks, and any combination thereof madeof steel, iron, aluminum, and other metals, plastic, fiberglass andother synthetic materials, wood, refractory materials, and anycombination thereof. For example, the foundation 4376 in the illustratedembodiment of FIG. 43 comprises a wood frame 4380 to which are attachedlegs 4382 for supporting the frame 4380 over a floor surface. Otherfoundation constructions and materials are possible, and fall within thespirit and scope of the present invention.

In some embodiments of the present invention, one or more bottom-mostlayers of any of the body supports disclosed herein can be separate fromthe other layers of the body support, and can be attached to a bodysupport foundation (such as any of the body support foundationembodiments described above in connection with the embodiment of FIG.43). In some embodiments, the bottom-most layer(s) can be permanentlycoupled to the body support foundation, such as by adhesive or cohesivebonding material, stitching (e.g., into a fabric or other sheet materialcovering of the foundation), double-sided tape, conventional fasteners,and the like. Alternatively, the bottom-most layer(s) can be releasablycoupled to the body support foundation, such as by one or more zippers,straps, buttons, clasps, laces, pieces of hook and loop fastenermaterial, hook and eye sets, tied ribbons, strings, cords, or othersimilar elements on the bottom-most layer(s) and/or on the foundation.In still other embodiments, the bottom-most layer(s) can be coupled tothe body support by a cover (described above), such as by coupling thecover of the bottom-most layer(s) to the foundation (e.g., by staples,tacks nails, brads, rivets, and other conventional fasteners) or bypermanently or releasably coupling the cover to the foundation in any ofthe manners described above with reference to connections between thebottom-most layer(s) and the foundation.

For example, the bottom cover 4374 of the embodiment illustrated in FIG.43 can be permanently secured by nails or staples to the foundation4376. The bottom cover 4374 can enclose any or all of the bottom layer4314 of relatively highly resilient flexible cellular foam, and canenclose any part or all of the foundation 4376 (although in someembodiments, the bottom cover 4374 covers substantially none of thefoundation 4376).

By utilizing a body support construction in which one or more of thelayers of the body support are separate from one or more other layers ofthe body support (i.e., are shipped separately from, are releasablyconnected to, and/or are not connected to such other layer(s)), a bodysupport and foundation assembly can be provided that can be easierand/or less expensive to ship, move, and assemble. In some embodiments,it is not practical or economical to manufacture and ship thicker bodysupports based at least in part upon the weight and size of suchsupports. An option is to provide the thicker body supports in two ormore separate pieces. However, the purchase and shipment of separatebody support pieces (in addition to a separate foundation) is not alwaysattractive to manufacturers, distributors, or purchasers. By permanentlyor releasably coupling one or more layers of the body support to thefoundation, a relatively thick body support can still be provided whileavoiding the disadvantages of two or more separate body support piecesin addition to a foundation. Also, such a body support and foundationconstruction can enable the manufacture and shipment of still thickerbody supports that would otherwise be too bulky or heavy to move.

It will be appreciated that the above description of the covers 4372,4374 applies equally to other covers utilized to at least partiallyenclose any one or more layers in any of the other body supportembodiments disclosed herein. It will also be appreciated that the abovedescription of the foundation 4376 applies equally to the support of anyof the other body support embodiments disclosed herein.

The embodiments described above and illustrated in the figures arepresented by way of example only and are not intended as a limitationupon the concepts and principles of the present invention. As such, itwill be appreciated by one having ordinary skill in the art that variouschanges in the elements and their configuration and arrangement arepossible without departing from the spirit and scope of the presentinvention as set forth in the appended claims.

For example, the reticulated and non-reticulated visco-elastic foamutilized in the various embodiments of the present invention describedand illustrated herein can be made from a polyurethane foam. However, itshould be noted that any other visco-elastic polymer material exhibitingsimilar properties (e.g., thermally-responsive properties) can insteadbe used as desired.

Also, several of the body support embodiments disclosed herein utilizeone or more non-planar surface shapes in order to define passagesthrough which air can move and/or to increase the ability of heat todissipate within the body support. Although the locations of suchnon-planar surfaces as described above in the various embodiments canprovide significant performance advantages for the body supports, suchnon-planar surface shapes can be utilized between any two adjacentlayers in any of the body support embodiments disclosed herein. Furtherdetails of such non-planar surface shapes are provided above inconnection with the illustrated embodiment of FIG. 4.

It should be noted that the various body supports described andillustrated herein can be utilized alone or in combination with one ormore other layers of material. Such additional layers of material cancomprise any of the foam materials described herein (or other materials,as desired), can be located beneath and support the disclosed bodysupport, and can be permanently or releasably coupled to the disclosedbody support.

As described in greater detail above, some embodiments of the presentinvention have a relatively thin cover of reticulated non-visco-elasticfoam covering one or more surfaces of one or more layers of the bodysupport (e.g., see the embodiments of FIGS. 9, 29, and 30). Thereticulated non-visco-elastic foam cover can be selected to provide aheightened degree of fire resistance to the body support, can beutilized in some countries and/or localities to meet fire codes callingfor such fire resistance, and can provide improved ventilation and/orheat dissipation for surfaces of one or more adjacent body supportlayers based at least in part upon the skeletal cellular structure ofthe reticulated non-visco-elastic foam. Although the reticulated foamcovers described above comprise non-visco-elastic foam, it will beappreciated that such reticulated foam covers can instead comprisevisco-elastic foam. Also, the reticulated foam covers in the embodimentsof FIGS. 9, 29, and 30 are disclosed by way of example, it beingunderstood that reticulated visco-elastic or reticulatednon-visco-elastic foam covers can cover any exterior surface of any ofthe layers in any of the other body support embodiments disclosedherein.

A number of the body support embodiments disclosed herein employ one ormore layers of material having different types of material in differentareas of the same layer (e.g., see the embodiments of FIGS. 7-9 and31-34). It should be noted that such layers can be utilized in otherbody supports having different underlying and/or overlying layers whilestill performing some or all of their functions described above. Suchalternate body supports and fall within the spirit and scope of thepresent invention.

1. A support cushion, comprising: a first layer comprising visco-elastic foam having an exposed top surface; and a bottom surface opposite the top surface and separated from the top surface by a distance defining a thickness of the support cushion; wherein at least a portion of the exposed top surface of the top layer has a convoluted shape.
 2. The support cushion as claimed in claim 1, further comprising a cover at least partially covering the exposed top surface of the first layer.
 3. The support cushion as claimed in claim 1, wherein the first layer comprises a plurality of cells defining a reticulated cellular structure, the cells of the reticulated cellular structure comprising a skeletal plurality of supports through which substantially open cell walls establish fluid communication between an interior of the cell and interiors of adjacent cells.
 4. The support cushion as claimed in claim 3, wherein the first layer comprises foam having a density no less than about 30 kg/m³ and no greater than about 175 kg/m³, and a hardness of no less than about 20 N and no greater than about 150 N at 40% indentation force defection measured at about 22 degrees Celsius, the layer of flexible foam comprising visco-elastic foam having at least one material property responsive to a temperature change in a range of 10-30° C.
 5. The support cushion as claimed in claim 4, wherein the first layer comprises foam having a density no less than about 50 kg/m³ and no greater than about 130 kg/m³.
 6. The support cushion as claimed in claim 4, wherein the first layer comprises foam has a density no less than about 60 kg/m³ and no greater than about 110 kg/m³.
 7. The support cushion as claimed in claim 1, further comprising a second layer of polyurethane foam located beneath the first layer, the second layer of polyurethane foam having a hardness of at least about 50 N.
 8. The support cushion as claimed in claim 1, further comprising a second layer of polyurethane foam located beneath the first layer, the second layer of polyurethane foam having a hardness of at least about 80 N.
 9. The support cushion as claimed in claim 1, further comprising a second layer of flexible foam supporting the first layer, the second layer of flexible foam having a plurality of cells defining a reticulated cellular structure and having a temperature change responsiveness of no greater than 10% change in hardness within a temperature range of 10-30 degrees Celsius.
 10. The support cushion as claimed in claim 9, wherein the first layer comprises visco-elastic foam having a non-reticulated visco-elastic cellular structure having a density no less than about 30 kg/m³ and no greater than about 150 kg/M³; a hardness of no less than about 30 N and no greater than about 175 N at 40% indentation force defection measured at about 22 degrees Celsius; and at least one material property responsive to a temperature change in a range of 10-30° C. 